On-board charging station for a remote control device

ABSTRACT

A system is provided comprising: a materials handling vehicle; a wearable remote control device comprising: a wireless communication system including a wireless transmitter; and a rechargeable power source; a receiver at the vehicle for receiving transmissions from the wireless transmitter; a controller at the vehicle that is communicably coupled to the receiver, the controller being responsive to receipt of the transmissions from the remote control device; and a charging station at the vehicle. The charging station may charge the rechargeable power source of the wearable remote control device. The charging station may comprise a visual indicator.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 63/059,567, filed Jul. 31, 2020, entitled “ON-BOARDCHARGING STATION FOR A REMOTE CONTROL DEVICE”, and 63/105,479, filedOct. 26, 2020, entitled “ON-BOARD CHARGING STATION FOR A REMOTE CONTROLDEVICE”; the disclosures of which are hereby incorporated by reference.This application is a continuation-in-part of U.S. application Ser. No.16/718,473, filed Dec. 18, 2019, entitled “PAIRING A REMOTE CONTROLDEVICE TO A VEHICLE,” and Ser. No. 16/718,411, filed Dec. 18, 2019,entitled “ON-BOARD CHARGING STATION FOR A REMOTE CONTROL DEVICE,” whichboth claim the benefit of U.S. Provisional Application No. 62/800,032,filed Feb. 1, 2019, the disclosures of which are incorporated herein byreference.

BACKGROUND

Materials handling vehicles are commonly used for picking stock inwarehouses and distribution centers. Such vehicles typically include apower unit and a load handling assembly, which may include load carryingforks. The vehicle also has control structures for controlling operationand movement of the vehicle.

In a typical stock picking operation, an operator fills orders fromavailable stock items that are located in storage areas provided alongone or more aisles of a warehouse or distribution center. The operatordrives the vehicle between various pick locations where item(s) are tobe picked. The operator may drive the vehicle either by using thecontrol structures on the vehicle, or via a wireless remote controldevice that is associated with the vehicle, such as the remote controldevice disclosed in commonly owned U.S. Pat. No. 9,082,293, the entiredisclosure of which is hereby incorporated by reference herein.

SUMMARY

In accordance with a first aspect, a system is provided comprising: amaterials handling vehicle; a wearable remote control device comprising:a wireless communication system including a wireless transmitter; and arechargeable power source; a receiver at the vehicle for receivingtransmissions from the wireless transmitter; a controller at the vehiclethat is communicably coupled to the receiver, the controller beingresponsive to receipt of the transmissions from the remote controldevice; and a charging station at the vehicle. The charging station maycharge the rechargeable power source of the wearable remote controldevice. The charging station may comprise a visual indicator configuredto indicate one or more of: a charging state of the rechargeable powersource when coupled to the charging station, a charging state of therechargeable power source when removed from the charging station, apairing status between the wearable remote control device and thevehicle controller, or that the remote control device is physicallyconnected to the charging station.

The visual indicator may display a first color when the remote controldevice is attached to the charging station. The visual indicator maydisplay a second color when the remote control device has been paired tothe vehicle controller.

The visual indicator may provide one of a flash display or a fullyfilled display.

The visual indicator may provide a visual indication as a cue for anoperator to perform an action. The action may be a test to confirm thatthe remote control device is functional and can communicate with thevehicle.

The visual indicator may define a first visual indicator, and thecharging station may further comprise a second visual indicator. Thefirst visual indicator and the second visual indicator may be configuredto be activated independently of each other such that either the firstvisual indicator is activated while the second visual indicator is notactivated or the second visual indicator is activated while the firstvisual indicator is not.

The first visual indicator when activated may provide one of anintermittent display or a steady-state display.

The intermittent display may be operational at a first pulsing rate or asecond pulsing rate, wherein the first and second rates vary infrequency.

The second visual indicator when activated may provide one of anintermittent display, a partially filled display or a steady-statedisplay.

The first visual indicator and the second indicator may be configured tobe concurrently activated.

The first visual indicator may be located proximate to a docking port ofthe charging station configured to receive the wearable remote controldevice and may be shaped to correspond to a graphic provided on thewearable remote control device to aid a user in positioning andconnecting the wearable remote control device to the docking port of thecharging station.

The first visual indicator may define a visual display related toinserting the wearable remote control device into the charging station.

The first or second visual indicators either individually or incombination with one another may provide a visual display related to thecharging station being enabled or disabled.

The first or second visual indicators either individually or incombination with one another may provide a visual display related to acharging error occurring with the charging station or the rechargeablepower source.

The first or second visual indicators either individually or incombination with one another may provide a visual display related to apairing error occurring between the wearable remote control device andthe vehicle.

The first or second visual indicators either individually or incombination with one another may provide a visual display related to acommunication error occurring between the wearable remote control deviceand the controller.

When the vehicle is turned on, the first indicator may pulse until theremote control device is connected to a docking port of the chargingstation such that the first indicator is turned OFF when the remotecontrol device is connected to the docking port.

When the vehicle is turned on, the first indicator pulses until theremote control device is connected to a docking port of the chargingstation, changes to a steady state ON display after the remote controldevice is connected to the docking port and remains ON providing thesteady state ON display until the rechargeable power source is fullycharged.

In accordance with a second aspect, a method is provided for coupling awearable remote control device to a charging station, wherein thewearable remote control device may comprise a wireless transmitter, arechargeable power source, and at least one control causing the wirelesstransmitter to wirelessly transmit a request to a controller of amaterials handling vehicle; and wherein the materials handling vehiclemay comprise a receiver for receiving transmissions from the wirelesstransmitter. The controller may be communicably coupled to the receiverand may be responsive to receipt of the transmissions from the remotecontrol device. The charging station may be configured for charging therechargeable power source of the wearable remote control device and maycomprise a visual indicator. The method may comprise: displaying, by thevisual indicator, an indication of one or more of: a charging state ofthe rechargeable power source when coupled to the charging station, acharging state of the rechargeable power source when removed from thecharging station, a pairing status between the wearable remote controldevice and the vehicle controller, or that the remote control device isphysically connected to the charging station.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIGS. 1 and 2 are side and top views of a materials handling vehiclecapable of remote wireless operation according to various aspects of thepresent invention;

FIG. 2A is a side view of another materials handling vehicle capable ofremote wireless operation according to various aspects of the presentinvention;

FIG. 3 is a schematic diagram of several components of a materialshandling vehicle capable of remote wireless operation according tovarious aspects of the present invention;

FIGS. 4-7 are views of a remote control device according to variousaspects of the present invention;

FIGS. 8A and 8B are cut away views showing a remote control device beingengaged with a charging station according to various aspects of thepresent invention;

FIGS. 9 and 10 are views of another remote control device according tovarious aspects of the present invention;

FIG. 11 is a schematic diagram of several components of a chargingstation according to various aspects of the present invention;

FIGS. 12-14 are views showing a remote control device and a chargingstation according to various aspects of the present invention;

FIG. 15 is a schematic diagram of several components of a remote controldevice according to various aspects of the present invention;

FIG. 16 depicts a method according to various aspects of the presentinvention;

FIG. 17 depicts a pairing method according to various aspects of thepresent invention;

FIG. 18 depicts another pairing method according to various aspects ofthe present invention;

FIG. 19 depicts a method to re-pair a vehicle and a remote-controldevice according to various aspects of the present invention;

FIG. 20 depicts a method to reestablish communication between a vehicleand a remote-control device according to various aspects of the presentinvention;

FIG. 21 depicts a method to charge a remote control device according tovarious aspects of the present invention;

FIG. 22 depicts another method to charge a remote control deviceaccording to various aspects of the present invention;

FIG. 23 is a schematic diagram of several components of a kit accordingto various aspects of the present invention;

FIG. 24 is a view of another remote control device according to variousaspects of the present invention;

FIG. 25 is a schematic diagram illustrating various aspects of thepresent invention;

FIGS. 26 and 27 illustrate a remote control device and a chargingstation constructed in accordance with a further embodiment;

FIGS. 28A-28I illustrate various states for first and second visualindicators of the charging station of FIGS. 26 and 27 ; and

FIGS. 29A-29C illustrate various states for first and second visualindicators of the charging station of FIGS. 26 and 27 .

DETAILED DESCRIPTION

In the following detailed description of the illustrated embodiments,reference is made to the accompanying drawings that form a part hereof,and in which is shown by way of illustration, and not by way oflimitation, specific embodiments in which the invention may bepracticed. It is to be understood that other embodiments may be utilizedand that changes may be made without departing from the spirit and scopeof various embodiments of the present invention.

Low Level Order Picking Truck

Referring now to the drawings, and particularly to FIGS. 1 and 2 , amaterials handling vehicle 10, which is illustrated as a low level orderpicking truck, includes a load handling assembly 12 that extends from apower unit 14. The vehicle 10 forms part of a system 8 according toaspects of the invention, which system 8 will be more fully describedbelow. The load handling assembly 12 includes a pair of forks 16, eachfork 16 having a load supporting wheel assembly 18. The load handlingassembly 12 may include other load handling features in addition to, orin lieu of the illustrated arrangement of the forks 16, such as a loadbackrest, scissors-type elevating forks, outriggers or separate heightadjustable forks, as a few examples. Still further, the load handlingassembly 12 may include load handling features such as a mast, a loadplatform, a collection cage or other support structure carried by theforks 16 or otherwise provided for handling a load supported and carriedby the vehicle 10. While the present disclosure is made with referenceto the illustrated vehicle 10, it will be apparent to those of skill inthe art that the vehicle 10 may comprise a variety of other industrialvehicles, such as a forklift truck, a reach truck, etc., and that thefollowing description of the invention with reference to the Figuresshould not be limited to an order picking truck unless otherwisespecified. Additionally, the vehicle 10 may be implemented in otherformats, styles and features, including a vehicle 10 that does notinclude a load handling assembly, such as a tugger vehicle, etc.

The illustrated power unit 14 comprises a step-through operator'sstation 20 dividing a first end section of the power unit 14 (oppositethe forks 16) from a second end section (proximate the forks 16). Theoperator's station 20 includes a platform 21 upon which an operator maystand to drive the vehicle 10 and/or to provide a position from whichthe operator may operate various included features of the vehicle 10.

Presence sensors 22 (see FIG. 2 ) may be provided to detect the presenceof an operator on the vehicle 10. For example, presence sensors 22 maybe located on, above or under the platform 21, or otherwise providedabout the operator's station 20. In the exemplary vehicle 10 of FIG. 2 ,the presence sensors 22 are shown in dashed lines indicating that theyare positioned underneath the platform 21. Under this arrangement, thepresence sensors 22 may comprise load sensors, switches, etc. As analternative, the presence sensors 22 may be implemented above theplatform 21, such as by using ultrasonic, capacitive or other suitablesensing technology. The utilization of presence sensors 22 will bedescribed in greater detail herein.

According to one embodiment shown in FIG. 2 , the vehicle 10 may includea pole that extends vertically from the power unit 14 and includes anantenna 30 that is provided for receiving control signals from acorresponding wireless remote control device 32. The pole may include alight 33 at the top, as shown in FIGS. 1 and 2 . According to anotherembodiment as shown in FIG. 2A, the antenna may be located within othervehicle components, such that the control signals from the remotecontrol device 32 are received elsewhere on the vehicle 10, as will bediscussed below. The remote control device 32 comprises an additionalcomponent of the system 8 to be described in more detail below.

The remote control device 32 is manually operable by an operator, e.g.,by pressing a button or other control, to cause the remote controldevice 32 to wirelessly transmit at least a first type signaldesignating a travel request to a vehicle 10 that is paired to theremote control device 32. The travel request is a command that requeststhe vehicle 10 to travel, as will be described in greater detail herein.Although the remote control device 32 is illustrated in FIGS. 1 and 2 asa finger-mounted structure, numerous implementations of the remotecontrol device 32 may be implemented, including for example, a glovestructure, a lanyard or sash mounted structure, etc. Still further, thevehicle 10 and the remote control device 32 may comprise any additionaland/or alternative features or implementations, examples of which aredisclosed in U.S. Provisional Patent Application Ser. No. 60/825,688,filed Sep. 14, 2006, entitled “SYSTEMS AND METHODS OF REMOTELYCONTROLLING A MATERIALS HANDLING VEHICLE;” U.S. patent application Ser.No. 11/855,310, filed Sep. 14, 2007, entitled “SYSTEMS AND METHODS OFREMOTELY CONTROLLING A MATERIALS HANDLING VEHICLE” now U.S. Pat. No.9,082,293; U.S. patent application Ser. No. 11/855,324, filed Sep. 14,2007, entitled “SYSTEMS AND METHODS OF REMOTELY CONTROLLING A MATERIALSHANDLING VEHICLE” now U.S. Pat. No. 8,072,309; U.S. Provisional PatentApplication Ser. No. 61/222,632, filed Jul. 2, 2009, entitled “APPARATUSFOR REMOTELY CONTROLLING A MATERIALS HANDLING VEHICLE;” U.S. patentapplication Ser. No. 12/631,007, filed Dec. 4, 2009, entitled “MULTIPLEZONE SENSING FOR MATERIALS HANDLING VEHICLES” now U.S. Pat. No.9,645,968; U.S. Provisional Patent Application Ser. No. 61/119,952,filed Dec. 4, 2008, entitled “MULTIPLE ZONE SENSING FOR REMOTELYCONTROLLED MATERIALS HANDLING VEHICLES;” and/or U.S. Pat. No. 7,017,689,issued Mar. 28, 2006, entitled “ELECTRICAL STEERING ASSIST FOR MATERIALHANDLING VEHICLE”; the entire disclosures of which are each herebyincorporated by reference herein. Additional details in connection withthe remote control device 32 will be discussed in detail below.

The vehicle 10 also comprises one or more contactless obstacle sensors40, which are provided about the vehicle 10, e.g., towards the first endsection of the power unit 14 as shown in FIGS. 1 and 2 . The obstaclesensors 40 are operable to define at least one detection zone. Forexample, at least one detection zone may define an area at leastpartially in front of a forward traveling direction of the vehicle 10when the vehicle 10 is traveling in response to a wirelessly receivedtravel request from the remote control device 32, as will also bedescribed in greater detail herein.

The obstacle sensors 40 may comprise any suitable proximity detectiontechnology, such as ultrasonic sensors, image capture devices, infraredsensors, laser scanner sensors, etc., which are capable of detecting thepresence of objects/obstacles or are capable of generating signals thatcan be analyzed to detect the presence of objects/obstacles within thepredefined detection zone(s). In the exemplary embodiment illustrated inFIGS. 1 and 2 , the vehicle 10 includes a first obstacle detector 42 anda pair of second obstacle detectors 44A and 44B mounted to the powerunit 14. The first obstacle detector 42 is spaced apart from the secondobstacle detectors 44A and 44B along a vertical axis VA of the vehicle10 defining a vertical direction, i.e., the second obstacle detectors44A and 44B are located below (closer to the ground than) the firstobstacle detector 42, see FIG. 1 . The second obstacle detectors 44A and44B are spaced apart from each other along a horizontal axis HA of thevehicle 10 defining a horizontal direction, see FIG. 2 .

The first obstacle detector 42 may comprise a sweeping laser sensorcapable of detecting objects, for example, in first, second, and thirdzones Z₁, Z₂, Z₃ (also referred to herein as scan zones or detectionzones), which first, second, and third zones Z₁, Z₂, Z₃ may compriseplanar zones, see FIGS. 1 and 2 . The second zone Z₂ may comprise a“stop zone”, and the first and third zones Z₁ and Z₃ may comprise leftand right “steer bumper zones”, such as the stop zone and the left andright steer bumper zones described in U.S. Pat. No. 8,452,464, issuedMay 28, 2013, entitled “STEER CORRECTION FOR A REMOTELY OPERATEDMATERIALS HANDLING VEHICLE”, the entire disclosure of which isincorporated by reference herein. It is noted that the first obstacledetector 42 may be capable of detecting objects in additional or fewerzones than the three zones Z₁, Z₂, Z₃ illustrated. In one exemplarydetection zone configuration, any or all of the detection zones may beused as disclosed in U.S. Pat. No. 9,002,581 issued Apr. 7, 2015 andentitled “OBJECT TRACKING AND STEER MANEUVERS FOR MATERIALS HANDLINGVEHICLES”, the entire disclosure of which is incorporated by referenceherein.

The second obstacle detectors 44A and 44B may comprise point lasersensors that are capable of detecting objects between one or more of thezones Z₁, Z₂, Z₃ of the first obstacle detector 42 and the vehicle 10,i.e., underneath one or more of the zones Z₁, Z₂, Z₃, as illustrated inFIG. 1 , and/or past the zones Z₁, Z₂, Z₃, and are preferably capable ofat least detecting objects underneath the second zone Z₂. The secondobstacle detectors 44A and 44B are thus capable of detecting objectslocated in a non-detect zone DZ of the first obstacle detector 42, seeFIG. 1 , i.e., which non-detect zone DZ is defined as an area below thezones Z₁, Z₂, Z₃ and thus not sensed by the first obstacle detector 42.Hence, the first obstacle detector 42 functions to detect objectslocated along a path of travel of the power unit 14 beyond thenon-detect zone DZ, while the second obstacle detectors 44A and 44Bfunction to sense objects along the path of travel of the power unit 14in the non-detect zone DZ, which is located just in front of the vehicle10, as shown in FIG. 1 .

Additional sensor configurations and/or detection zones may be used,such as discussed in the various patents and patent applicationsincorporated by reference herein.

The vehicle 10 shown in FIGS. 1 and 2 further includes a chargingstation 50 that comprises an additional component of the system 8 andthat is provided for charging a rechargeable power source of the remotecontrol device 32. Additional details in connection with the chargingstation 50 will be described below.

Control System for Remote Operation of a Low Level Order Picking Truck

Referring to FIG. 3 , a block diagram illustrates a control arrangementfor integrating remote control commands with the vehicle 10. A receiver102, which may be a Bluetooth Low Energy (BLE) radio, for example, isprovided for receiving commands issued by the remote control device 32.The receiver 102 passes the received control signals to a controller103, which implements the appropriate response to the received commandsand may thus also be referred to herein as a master controller. In thisregard, the controller 103 is implemented in hardware and may alsoexecute software (including firmware, resident software, micro-code,etc.). Furthermore, aspects of the present invention may take the formof a computer program product embodied in one or more computer readablemedium(s) having computer readable program code embodied thereon. Forexample, the vehicle 10 may include memory that stores the computerprogram product, which, when implemented by a processor of thecontroller 103, implements steer correction as described more fullyherein.

Thus, the controller 103 may define, at least in part, a data processingsystem suitable for storing and/or executing program code and mayinclude at least one processor coupled directly or indirectly to memoryelements, e.g., through a system bus or other suitable connection. Thememory elements can include local memory employed during actualexecution of the program code, memory that is integrated into amicrocontroller or application specific integrated circuit (ASIC), aprogrammable gate array or other reconfigurable processing device, etc.

The response implemented by the controller 103 in response to wirelesslyreceived commands, e.g., via a wireless transmitter 178 of the remotecontrol device 32 (to be discussed below) and sent to the receiver 102on the vehicle 10, may comprise one or more actions, or inaction,depending upon the logic that is being implemented. Positive actions maycomprise controlling, adjusting or otherwise affecting one or morecomponents of the vehicle 10. The controller 103 may also receiveinformation from other inputs 104, e.g., from sources such as thepresence sensors 22, the obstacle sensors 40, switches, load sensors,encoders and other devices/features available to the vehicle 10 todetermine appropriate action in response to the received commands fromthe remote control device 32. The sensors 22, 40, etc. may be coupled tothe controller 103 via the inputs 104 or via a suitable truck network,such as a control area network (CAN) bus 110.

In an exemplary arrangement, the remote control device 32 is operativeto wirelessly transmit a control signal that represents a first typesignal such as a travel command to the receiver 102 on the vehicle 10.The travel command is also referred to herein as a “travel signal”,“travel request” or “go signal”. The travel request is used to initiatea request to the vehicle 10 to travel, e.g., for as long as the travelsignal is received by the receiver 102 and/or sent by the remote controldevice 32, by a predetermined amount, e.g., to cause the vehicle 10 toadvance or jog in a first direction by a limited travel distance, or fora limited time. The first direction may be defined, for example, bymovement of the vehicle 10 in a power unit 14 first, i.e., forks 16 tothe back, direction. However, other directions of travel mayalternatively be defined. Moreover, the vehicle 10 may be controlled totravel in a generally straight direction or along a previouslydetermined heading. Correspondingly, the limited travel distance may bespecified by an approximate travel distance, travel time or othermeasure.

Thus, a first type signal received by the receiver 102 is communicatedto the controller 103. If the controller 103 determines that the travelsignal is a valid travel signal and that the current vehicle conditionsare appropriate (explained in greater detail in U.S. Pat. No. 9,082,293,which is already incorporated by reference herein), the controller 103sends a signal to the appropriate control configuration of the vehicle10 to advance and then stop the vehicle 10. Stopping the vehicle 10 maybe implemented, for example, by either allowing the vehicle 10 to coastto a stop or by initiating a brake operation to cause the vehicle 10 tobrake to a stop.

As an example, the controller 103 may be communicably coupled to atraction control system, illustrated as a traction motor controller 106of the vehicle 10. The traction motor controller 106 is coupled to atraction motor 107 that drives at least one steered wheel 108 of thevehicle 10. The controller 103 may communicate with the traction motorcontroller 106 so as to accelerate, decelerate, adjust and/or otherwiselimit the speed of the vehicle 10 in response to receiving a travelrequest from the remote control device 32. The controller 103 may alsobe communicably coupled to a steer controller 112, which is coupled to asteer motor 114 that steers at least one steered wheel 108 of thevehicle 10. In this regard, the vehicle 10 may be controlled by thecontroller 103 to travel an intended path or maintain an intendedheading in response to receiving a travel request from the remotecontrol device 32.

As yet another illustrative example, the controller 103 may becommunicably coupled to a brake controller 116 that controls vehiclebrakes 117 to decelerate, stop or otherwise control the speed of thevehicle 10 in response to receiving a travel request from the remotecontrol device 32. Still further, the controller 103 may be communicablycoupled to other vehicle features, such as main contactors 118, and/orother outputs 119 associated with the vehicle 10, where applicable, toimplement desired actions in response to implementing remote travelfunctionality.

According to various aspects of the present invention, the controller103 may communicate with the receiver 102 and with the traction motorcontroller 106 to operate the vehicle 10 under remote control inresponse to receiving travel commands from the associated remote controldevice 32. Moreover, the controller 103 may be configured to performvarious actions if the vehicle 10 is traveling under remote control inresponse to a travel request and an obstacle is detected in one or moreof the detection zone(s) Z₁, Z₂, Z₃. In this regard, when a travelsignal is received by the controller 103 from the remote control device32, any number of factors may be considered by the controller 103 todetermine whether the received travel signal should be acted upon toinitiate and/or sustain movement of the vehicle 10.

Correspondingly, if the vehicle 10 is moving in response to a commandreceived by the remote control device 32, the controller 103 maydynamically alter, control, adjust or otherwise affect the remotecontrol operation, e.g., by stopping the vehicle 10, changing the steerangle of the vehicle 10, or taking other actions. Thus, the particularvehicle features, the state/condition of one or more vehicle features,vehicle environment, etc., may influence the manner in which thecontroller 103 responds to travel requests from the remote controldevice 32.

The controller 103 may refuse to acknowledge a received travel requestdepending upon predetermined condition(s), e.g., that relate toenvironmental or operational factor(s). For example, the controller 103may disregard an otherwise valid travel request based upon informationobtained from one or more of the sensors 22, 40. As an illustration,according to various aspects of the present invention, the controller103 may optionally consider factors such as whether an operator is onthe vehicle 10 when determining whether to respond to a travel commandfrom the remote control device 32. As noted above, the vehicle 10 maycomprise at least one presence sensor 22 for detecting whether anoperator is positioned on the vehicle 10. In this regard, the controller103 may be further configured to respond to a travel request to operatethe vehicle 10 under remote control when the presence sensor(s) 22designate that no operator is on the vehicle 10. Thus, in thisimplementation, the vehicle 10 cannot be operated in response towireless commands from the remote control device 32 unless the operatoris physically off of the vehicle 10. Similarly, if the obstacle sensors40 detect that an object, including the operator, is adjacent and/orproximate to the vehicle 10, the controller 103 may refuse toacknowledge a travel request from the remote control device 32. Thus, inan exemplary implementation, an operator must be located within alimited range of the vehicle 10, e.g., close enough to the vehicle 10 tobe in wireless communication range (which may be limited to set amaximum distance of the operator from the vehicle 10). Otherarrangements may alternatively be implemented.

Any other number of reasonable conditions, factors, parameters or otherconsiderations may also/alternatively be implemented by the controller103 to interpret and take action in response to received signals fromthe transmitter 178. Other exemplary factors are set out in greaterdetail in U.S. Provisional Patent Application Ser. No. 60/825,688,entitled “SYSTEMS AND METHODS OF REMOTELY CONTROLLING A MATERIALSHANDLING VEHICLE;” U.S. patent application Ser. No. 11/855,310, entitled“SYSTEMS AND METHODS OF REMOTELY CONTROLLING A MATERIALS HANDLINGVEHICLE” now U.S. Pat. No. 9,082,293; U.S. patent application Ser. No.11/855,324, entitled “SYSTEMS AND METHODS OF REMOTELY CONTROLLING AMATERIALS HANDLING VEHICLE” now U.S. Pat. No. 8,072,309; U.S.Provisional Patent Application Ser. No. 61/222,632, entitled “APPARATUSFOR REMOTELY CONTROLLING A MATERIALS HANDLING VEHICLE;” U.S. patentapplication Ser. No. 12/631,007, entitled “MULTIPLE ZONE SENSING FORMATERIALS HANDLING VEHICLES” now U.S. Pat. No. 9,645,968; and U.S.Provisional Patent Application Ser. No. 61/119,952, entitled “MULTIPLEZONE SENSING FOR REMOTELY CONTROLLED MATERIALS HANDLING VEHICLES;” thedisclosures of which are each already incorporated by reference herein.

Upon acknowledgement of a travel request, the controller 103 interactswith the traction motor controller 106, e.g., directly or indirectly,e.g., via a bus such as the CAN bus 110 if utilized, to advance thevehicle 10. Depending upon the particular implementation, the controller103 may interact with the traction motor controller 106 and optionally,the steer controller 112, to advance the vehicle 10 for as long as atravel control signal is received. Alternatively, the controller 103 mayinteract with the traction motor controller 106 and optionally, thesteer controller 112, to advance the vehicle 10 for a period of time orfor a predetermined distance in response to the detection and maintainedactuation of a travel control on the remote control device 32. Stillfurther, the controller 103 may be configured to “time out” and stop thetravel of the vehicle 10 based upon a predetermined event, such asexceeding a predetermined time period or travel distance regardless ofthe detection of maintained actuation of a corresponding control on theremote control device 32.

The remote control device 32 may also be operative to transmit a secondtype signal, such as a “stop signal”, designating that the vehicle 10should brake and/or otherwise come to rest. The second type signal mayalso be implied, e.g., after implementing a “travel” command, e.g.,after the vehicle 10 has traveled a predetermined distance, traveled fora predetermined time, etc., under remote control in response to thetravel command. If the controller 103 determines that a wirelesslyreceived signal is a stop signal, the controller 103 sends a signal tothe traction motor controller 106, the brake controller 116 and/or othertruck component to bring the vehicle 10 to a rest. As an alternative toa stop signal, the second type signal may comprise a “coast signal” or a“controlled deceleration signal” designating that the vehicle 10 shouldcoast, eventually slowing to rest.

The time that it takes to bring the vehicle 10 to a complete rest mayvary, depending for example, upon the intended application, theenvironmental conditions, the capabilities of the particular vehicle 10,the load on the vehicle 10 and other similar factors. For example, aftercompleting an appropriate jog movement, it may be desirable to allow thevehicle 10 to “coast” some distance before coming to rest so that thevehicle 10 stops slowly. This may be achieved by utilizing regenerativebraking to slow the vehicle 10 to a stop. Alternatively, a brakingoperation may be applied after a predetermined delay time to allow apredetermined range of additional travel to the vehicle 10 after theinitiation of the stop operation. It may also be desirable to bring thevehicle 10 to a relatively quicker stop, e.g., if an object is detectedin the travel path of the vehicle 10 or if an immediate stop is desiredafter a successful jog operation. For example, the controller 103 mayapply predetermined torque to the braking operation. Under suchconditions, the controller 103 may instruct the brake controller 116 toapply the brakes 117 to stop the vehicle 10.

Also shown in FIG. 3 is the on-vehicle charging station 50 that cancommunicate with the controller 103. As will be explained in more detailbelow, the charging station 50 can be used to charge a rechargeablepower source 180 of the wireless remote control device 32. The chargingstation 50 may be located on a side portion of the vehicle 10, forexample, proximate to the operator's station 20 near manual drivingcontrols of the vehicle 10 as shown in FIGS. 1 and 2 , or on a sidepanel of the power unit 14.

A pairing system 34 can utilize a close range system to wirelesslycommunicate with a compatible close range system on the wireless remotecontrol device 32. Using the pairing system 34, a vehicle 10 andwireless remote control device 32 can be “paired” such that a vehicle 10will transmit and receive messages from only its paired wireless remotecontrol device 32. In addition to, or as an alternative to close rangeor other types of wireless communications, such as near-fieldcommunication (NFC), the pairing system 34 can also use physicalcontacts that allow electrical communication between the remote controldevice 32 and the vehicle 10, at least for the initial pairingprocedure. For example, electrical contacts of the charging station 50used for charging the remote control device 32 could be used for pairingthe vehicle 10 to the remote control device 32, as will be described ingreater detail herein. The pairing system 34 includes components thatphysically implement the communication method (e.g., Bluetooth, NFC,BLE, Wi-Fi, etc.) used to send messages and includes components thatprogrammatically exchange information in an agreed upon protocol toestablish and maintain a pairing. Thus, the pairing system 34 includes adevice that can execute programmable instructions to implement apredetermined algorithm and protocol to accomplish pairing operations.

In FIG. 3 , the charging station 50, the receiver 102, and the pairingsystem 34 are depicted as distinct functional blocks. However, one ofordinary skill will recognize that two or more of these components canbe combined in a single element to provide a multi-function device.

System

As noted above, the vehicle 10 (including the charging station 50) andthe remote control device 32 form the system 8 in accordance with anaspect of the present invention. The remote control device 32 and thecharging station 50 will now be described in turn.

With reference to FIGS. 4-8 , the remote control device 32 according tothis embodiment is a finger-mounted device, although the remote controldevice 32 could take other forms, such as a glove-mounted device, awrist-mounted device, a lanyard-mounted device, etc. The remote controldevice 32 may be mountable over one finger, two fingers, or more thantwo fingers of the operator.

The remote control device 32 illustrated in FIGS. 4-8 comprises apolymeric rigid base 172 (see FIG. 6 ) and a polymeric rigid upperhousing 174. The base 172 and upper housing 174 are coupled together viaany suitable manner and define an internal area 176 for receivinginternal components of the remote control device 32, including awireless communication system 456 including a wireless transmitter 178,such as the wireless transmitter 178 described above with reference toFIG. 3 , and a rechargeable power source 180. In one exemplaryembodiment, the wireless transmitter 178 comprises a model BGM121manufactured by SiLabs. It is noted that the terms “transmitter” and“receiver” as used herein are intended to mean a device capable ofone-way communication, i.e., the device only transmits or receivessignals, or a device capable of two-way communication, such as atransceiver, which both transmits and receives signals.

The rechargeable power source 180 may be a super capacitor, a highcapacity battery, etc. For example, an AVX supercapacitor, modelSCCR20E335PRB can be used, which has a rated voltage of 3V and acapacitance of 3.3 F. The rechargeable power source 180 is small enoughto fit within the internal area 176 while also having enough capacity ona substantially full charge to yield a use period of the remote controldevice 32 of at least two hours, at least four hours, at least eighthours, or more. A use period of up to eight hours may be preferable tocorrespond with an eight-hour working shift for an operator.

A supercapacitor (also called a supercap or ultracapacitor) is ahigh-capacity capacitor with capacitance values much higher than othercapacitors but, typically with lower voltage limits that bridge the gapbetween electrolytic capacitors and rechargeable batteries. Theytypically store 10 to 100 times more energy per unit volume or mass thanelectrolytic capacitors, can accept and deliver charge much faster thanbatteries, and tolerate many more charge and discharge cycles thanrechargeable batteries. Because supercapacitors can be used inapplications requiring many rapid charge/discharge cycles, someembodiments of the remote control device 32 can include a supercapacitoras the rechargeable power source 180. In embodiments of the presentinvention, the current supplied to the supercapacitor can be limited toabout 2 A and can accomplish charging to a full charge in about 2seconds or less. Regardless of the specific type of rechargeable powersource 180 used, embodiments of the present invention contemplaterecharging the rechargeable power source 180 to a desired amount, suchas to a full charge state, or to a charge state less than asubstantially full charge state (as will be discussed in detail herein)via the charging station 50 within a desired charging period. The powersupplied to the rechargeable power source 180 by the charging station 50may be varied in accordance with the capacity of the rechargeable powersource 180, the desired charge amount, and/or the desired chargingperiod, as will be discussed in greater detail herein.

With reference to FIG. 6 , the remote control device 32 furthercomprises securing structure 188 for securing the remote control device32 to one or more fingers of the operator's hand. The securing structure188 in the embodiment shown in FIG. 6 comprises a holding strap 190 thatincludes, for example, hook and loop tape fasteners 191 to secure theholding strap 190 to a single finger, e.g., the index finger, of theoperator. The remote control device 32 is provided with first and secondslots 192A and 192B located on opposed ends of the remote control device32 for receiving the holding strap 190.

The holding strap 190 shown in FIG. 6 defines a first finger receivingarea 194 for receiving the single finger OF (see FIGS. 1 and 2 ) of anoperator using the remote control device 32. Both right and left handversions of the remote control device 32 may be created. The remotecontrol device 32 is releasably held on the operator's index finger viathe holding strap 190. In one exemplary embodiment, a first end 190A ofthe holding strap 190 is threaded through the first slot 192A and asecond end 190B of the holding strap 190 is threaded through the secondslot 192B. The first end 190A of the holding strap 190 may bepermanently fastened to the rigid base 172, e.g., via stitching orgluing, while the second end 190B of the holding strap 190 may bereleasably inserted through the second slot 192B and doubled back suchthat the hook and loop tape fasteners 191 are engaged with one anotherto fasten the holding strap 190 to the operator's finger. The holdingstrap 190 can be adjusted to accommodate fingers of different sizes orsuch that the remote control device 32 could be worn over a glove (notshown). It is noted that other types of holding straps 190 may be used.

The remote control device 32 further comprises at least one control,depicted in FIGS. 4-8 as first, second, and third controls 196A-C. Thecontrols 196A-C each comprise a button 197A-C and a two-state switch198A-C located underneath the corresponding button 197A-C. The switches198A-C are communicably coupled to the wireless communication system456, such that actuation of each one of the controls 196A-C causes thewireless transmitter 178 to wirelessly transmit a respective request tothe vehicle 10. In the exemplary remote control device 32 depicted inFIGS. 4-8 : the first control 196A comprises a travel button 197A that,when pressed, causes the wireless transmitter 178 to wirelessly transmita request for the vehicle 10 to travel across a floor surface; thesecond control 196B comprises a horn button 197B that, when pressed,causes the wireless transmitter 178 to wirelessly transmit a request forthe vehicle 10 to sound a horn/audible alarm; and the third control 196Ccomprises a brake button 197C that, when pressed, causes the wirelesstransmitter 178 to wirelessly transmit a request for the vehicle to stop(if moving under wireless control) and, optionally, power down.

The remote control device 32 is compact, and substantially the entiretyof the remote control device 32 is mountable and positioned directlyover the index finger of the operator. Hence, interference of theoperator performing working tasks caused by wearing the remote controldevice 32 is minimal or non-existent. The remote control device 32 isdurable and long lasting since the rigid base 172 and the upper housing174 are preferably formed from a durable and rigid polymeric material,such as acrylonitrile butadiene styrene (ABS), polycarbonate or nylon.The rigid base 172 and the upper housing 174 define a durable, generallynon-flexible and rigid structure.

An operator can easily actuate the travel button 197A manually viahis/her thumb to cause the wireless transmitter 178 to wirelesslytransmit at least a first type signal designating a travel request orcommand to the vehicle 10. It is contemplated that the travel requestmay result in the vehicle 10 traveling for as long as the operator holdsdown the travel button 197A, or by a predetermined distance or for apredetermined amount of time. The horn button 197B and the brake button197C can be actuated by the operator's opposite hand, for example.

As shown in FIGS. 4 and 5 , the remote control device 32 furthercomprises one or more charging contacts 210, it being noted thatadditional or fewer charging contacts 210 than the four shown may beused, e.g., one charging contact 210 or two or more charging contacts210 may be used. Additionally, the remote control device 32 furtherincludes one or more sensors in the form of first presence contacts 212,illustrated in FIGS. 4 and 5 as a single first presence contact 212located intermediate the four charging contacts 210. The charging andfirst presence contacts 210, 212 may be arranged within openings 214formed in an outer surface of the upper housing 174 of the remotecontrol device 32. The tops of the charging and first presence contacts210, 212 may be positioned below the outer surface of the upper housing,i.e., the charging and first presence contacts 210, 212 may be recessedwithin the openings 214, which may prevent damage to the charging andfirst presence contacts 210, 212 due to accidental contact. It is notedthat other configurations for the number, orientation, and placement ofthe charging contacts 210 and the first presence contact(s) 212 could beused without departing from the scope and spirit of the invention.

In embodiments, the charging contacts 210 mate or engage with elements,e.g., electrical contacts or charging elements 220 of the on-vehiclecharging station 50 (to be discussed below), and the first presencecontact 212 mates or engages with a complementary second sensor in theform of a second presence contact 222, such as a switch, pogo pin orpressure pin, for example, of the on-vehicle charging station 50, asshown in FIGS. 8A and 8B and will be described in more detail herein. Itis noted that one or more of the charging contacts 210 and correspondingcharging elements 220 may be provided for redundancy. In one example,the four charging contacts 210 illustrated in FIGS. 4-7 and fourcharging elements 220 illustrated in FIGS. 12-14 could be set up as twopairs of redundant contacts/elements 210/220, where charging of therechargeable power source 180 (as discussed below) is enabled as long asone charging contact 210 from each pair is engaged with and inelectrical communication with its corresponding charging element 220.

Embodiments of the present invention also contemplate contactless, orinduction, charging in which the rechargeable power source 180 of theremote control device 32 can be charged by the remote control device 32being in close proximity to, or on the surface of, a compatibleinduction charging station (not shown). Such an induction chargingstation may be located, for example, in a driving or steering control ofthe vehicle 10 such that the rechargeable power source 180 may becharged while the operator is manually driving the vehicle 10 from theoperator's station 20.

FIGS. 9 and 10 illustrate another exemplary remote control device 32,where like reference numbers correspond to similar components to thoselisted above for FIGS. 4-8 . The remote control device 32 according tothis embodiment is intended as a two-finger design, i.e., the securingstructure 188 in the embodiment shown in FIGS. 9 and 10 comprises aholding strap 190 that defines first and second finger receiving areas194, 195 for receiving the index and middle fingers of an operator usingthe remote control device 32. The remote control device 32 according toFIGS. 9 and 10 includes two charging contacts 210 instead of fourcharging contacts 210 in the remote control device 32 of FIGS. 4-8 . Theremaining components of the remote control device 32 of FIGS. 9 and 10may be generally the same as the remote control device 32 of FIGS. 4-8and thus will not be described in detail herein.

FIG. 11 provides a functional block-level diagram of a vehicle chargingstation 50 in accordance with the principles of the present invention inwhich the pairing system 34 is incorporated into the charging station50. As explained in more detail below, the charging station 50 caninclude the receiver 102, e.g., a Bluetooth Low Energy (BLE) radio 402that can communicate with the vehicle's controller 103. Although notshown, the communication can be through the vehicle's CAN bus and, thus,the charging station 50 can include a CAN bus interface. The chargingstation 50 can also include one or more light emitting diodes (LEDs) 404or other visual indicators that help convey information to an operator.For example, one LED may be used to indicate that a remote controldevice 32 is presently coupled with the charging station 50. Other LEDsmay indicate a current state of charge of the remote control device'srechargeable power source 180. A current limiter 406 or other protectioncircuitry can be provided that helps ensure a remote control device 32is safely re-charged as the current limiter 406 allows the voltage fromthe vehicle's power source to be provided to the charging elements 220of the charging station 50 for charging the remote control device'srechargeable power source 180. These charging elements 220 interfacewith the charging contacts 210 of the remote control device 32 andprovide the electrical connection between the vehicle's power source andthe rechargeable power source 180 of the remote control device 32. Thesecond presence contact 222 engages with the first presence contact 212to detect when a remote control device 32 is physically connected to thecharging station 50 such that the charging contacts 210 are engaged withthe charging elements 220. According to embodiments, upon the secondpresence contact 222 being engaged by the first presence contact 212,the pairing process is initiated.

It is noted that the first and second presence contacts 212, 222 canrespectively be provided on either the remote control device 32 or thecharging station 50. That is, while the second presence contact 222 isillustrated on the charging station 50 and the first presence contact212 on the remote control device 32, the second presence contact 222could be located on the remote control device 32 and the first presencecontact 212 could be located on the charging station 50.

The relationship between the second presence contact 222 and thecharging elements 220 is such that the charging contacts 210 of theremote control device 32 and the charging elements 220 of the chargingstation 50 are in contact with one another before the second presencecontact 222 engages the first presence contact 212 when a chargingprocedure is being initiated, see FIG. 8A, which shows that the heightof the second presence contact 222 is less than the height of thecharging elements 220, the heights measured with respect to top surfacesof element housings 220A and a second presence contact housing 222A fromwhich the respective charging elements 220 and second presence contact222 extend. The supply of power from the charging station 50 to theremote control device 32 via the charging elements/charging contacts220/210 is only initiated after the second presence contact 222 engagesthe first presence contact 212. During a charging procedure, thecharging contacts 210 of the remote control device 32 are engaged withthe charging elements 220 of the charging station 50, and the secondpresence contact 222 is engaged with the first presence contact 212,thus enabling the supply of power from the charging station 50 to theremote control device 32 via the charging elements/charging contacts220/210, see FIG. 8B. After the rechargeable power source 180 is chargedto the desired amount, e.g., fully charged or charged to a desiredamount less than fully charged as described herein, the supply of powerfrom the charging station 50 to the remote control device 32 via thecharging elements/charging contacts 220/210 is cut off. In the case thatthe remote control device 32 is removed from the charging station 50before the rechargeable power source 180 is charged to the desiredamount, as the remote control device 32 is removed from the chargingstation 50, the second presence contact 222 disengages from the firstpresence contact 212 prior to the charging elements 220 disengaging fromthe charging contacts 210. The supply of power from the charging station50 to the rechargeable power source 180 of the remote control device 32via the charging elements/charging contacts 220/210 is cut off when thesecond presence contact 222 disengages from the first presence contact212. This arrangement is intended to prevent arcing between the chargingelements 220 and the charging contacts 210. Using the first presencecontact 212 and second presence contact 222 in the form of a pogo pinprovides the following advantages: a precise control of the relativeheights of the second presence contact 222 and the charging elements220; a small footprint, a good seal, e.g., to prevent moisture fromentering the second presence contact housing 222A from around the secondpresence contact 222; and it allows for the differentiation between thefirst presence contact 212 and a foreign object, such as a piece ofmetal, which prevents electrical current from flowing into such aforeign object if it were to be placed in contact with the secondpresence contact 222 and one or more of the charging elements 220.

As an alternative to the presence contacts 212, 222 being used toinitiate the supply of power from the charging station 50 to the remotecontrol device 32, a separate switch may be present that the operatorengages to begin a charging operation. In one specific embodiment usinginduction charging, such a switch can be incorporated into the vehicle'ssteering control, such that the operator's gripping of the steeringcontrol is detected and charging is subsequently enabled.

Controls 414 for providing controlling signals to operate the LEDs 404can be from various sources. While the remote control device 32 isoperated within range of the charging station 50, the controller 103 canreceive information about the state of charge of the rechargeable powersource 180 and drive the display of the LEDs 404 to convey thisinformation utilizing a CAN bus interface, for example. When the remotecontrol device 32 is coupled with the charging station 50 the LEDs 404can be used to convey a) that a remote control device 32 is physicallyconnected to charging station 50, b) that there is a remote controldevice 32 presently paired with the controller 103 of the vehicle, c)the progress/charging state of a current charging operation, and/or d)the charging state of the rechargeable power source 180. The informationfor items c) and d) may be sent to the charging station 50 by the remotecontrol device 32, for example, over a Bluetooth Low Energy (BLE)connection, which BLE connection will be discussed in greater detailbelow. According to one aspect, since the pairing and charging processesare performed very quickly, the progress/charging state of a currentcharging operation may not be displayed by the LEDs 404. The remotecontrol device 32 may store its charging profile and then send thecharging profile to the charging station 50, e.g., over the BLEconnection, after the remote control device 32 is removed from thecharging station 50, wherein the charging profile may be evaluated, forexample, by the controller 103, to determine if a proper charge of therechargeable power source 180 occurred. The second presence contact 222can also send control signals to controls 414 that indicate whethercharging contacts 210 of the remote control device 32 are properlycoupled with corresponding charging elements 220 of the charging station50.

FIGS. 12-14 illustrate other features of the charging station 50 locatedat the vehicle 10. The charging station 50 can include one or morephysical protrusions or guide structures 420 that help guide the remotecontrol device 32 into correct alignment so that the station's chargingelements 220 are aligned with the charging contacts 210 of the remotecontrol device 32, i.e., the guide structure(s) 420 align the remotecontrol device 32 in the proper orientation for charging therechargeable power source 180. In FIG. 12 , a single guide structure 420including a plurality of guide surfaces is shown. The guide structure(s)420 can be placed around the location of the charging elements 220 andcan be shaped or slanted so that the remote control device 32 isphysically guided to correct alignment as the operator places the remotecontrol device 32 in the charging station 50.

In FIG. 13 , the LEDs 404 include a visual indicator 424 that indicatesa remote control device 32 is attached to the charging station 50. Thevisual indicator 424 may illuminate, flash, or progressively fill as afirst color to indicate that the remote control device 32 is attached tothe charging station 50, and as a second color or fully filled firstcolor to indicate that the remote control device 32 has been paired tothe vehicle controller 103, i.e., the visual indicator 424 may use thesecond color or fully filled first color to serve as a pairing indicatorthat confirms the establishment of communication between the remotecontrol device 32 and the vehicle 10. Additionally, according to oneoptional aspect of the invention, the LEDs 404 may flash, illuminate asa second color, or provide some other visual indication afterestablishment of communication between the remote control device 32 andthe vehicle 10 as a cue for the operator to perform an action as a testto confirm that the remote control device 32 is functional and cancommunicate to the vehicle 10, such as by pressing the horn button 197Band brake button 197C concurrently. It is understood that separateindicators may be used for the purposes of indicating that a remotecontrol device 32 is attached to the charging station 50 and to indicatethat the remote control device 32 has been paired to the vehicle 10, asopposed to a single indicator that can serve both functions.

The LEDs 404 can further serve as an indicator to identify the progressof a recharging operation when the remote control device 32 is attached.When the remote control device 32 is not attached to the chargingstation 50, the LEDs 404 may serve as an indicator to indicate thepresent state of charge of the rechargeable power source 180 of theremote control device 32. Thus, the LEDs 404 can indicate the state ofcharge of the rechargeable power source 180 both when charging therechargeable power source 180 at the charging station 50 and during useof the remote control device 32, i.e., while the operator is using theremote control device 32 to assist in performing work operations. In oneexemplary embodiment, the LEDs 404 can comprise a series of lights, eachlight representing a level of the state of charge of the rechargeablepower source 180.

In FIGS. 12 and 14 , an exemplary location of the second presencecontact 222 is shown within the charging station 50. It is noted thatthe remote control device 32 illustrated in FIGS. 12-14 is thesingle-finger embodiment of FIGS. 4-7 . It is also noted that thecharging contacts 210 and first presence contact 212 of thesingle-finger and the two-finger embodiments could be arranged to mirrorone another. Thus, the same charging station 50 could be used forinstances of the single-finger or two-finger remote control devices 32.

The charging station 50 may be located at various locations on thevehicle 10. Its location should be such that it does not interfere withnormal operation of the vehicle 10, but where it is accessible andconvenient for the operator. In embodiments the charging station 50 islocated in the operator's station 20 (see FIGS. 1 and 2 , where thecharging station 50 is located in the operator's station 20 but is alsoaccessible from outside of the vehicle 10), on a surface of one of thesides of the vehicle 10, or, for the induction charging embodiment,within the steering control of the vehicle 10.

The charging station 50 may include a voltage regulator (not shown) thattransforms the power from the vehicle 10 received by the chargingstation 50 into a regulated direct current (DC) voltage signal selectedbased on the charging characteristics of the rechargeable power source180. For example, in an embodiment in which the rechargeable powersource 180 is an AVX supercapacitor described above or equivalentdevice, a 3V DC (1%) supply voltage could be provided to the currentlimiter 406.

It is noted that the remote control device 32 is described herein ashaving an exemplary configuration and may be structurally modifiedwithout departing from the spirit and scope of the invention. Forexample, one or more components of the remote control device 32 may becombined in an integral component, or components may be substituted foralternate components that effect a similar/identical purpose.

In one embodiment, charging of the rechargeable power source 180 via thecharging station 50 occurs when one or more charging contacts 210 engagea corresponding charging element 220 of the charging station 50. In someembodiments, at least two charging contacts 210 or at least fourcharging contacts 210 and corresponding charging elements 220 arepresent. In some embodiments, one or more pairs of charging contacts 210are provided, wherein at least one charging contact 210 from each pairmust engage a corresponding charging element 220 for charging to occur.As described above, at least one of the remote control device 32 and thecharging station 50 can include a second presence contact 222, such as aswitch, for example. The second presence contact 222 detects whether ornot the at least one charging contact 210 is correctly engaged with theat least one corresponding charging element 220 for charging therechargeable power source 180, wherein if a correct engagement isdetected, the transfer of power to the rechargeable power source 180 isenabled by the charging station 50, and if a correct engagement is notdetected, the transfer of power to the rechargeable power source 180 isnot enabled by the charging station 50.

Furthermore, the arrangement of the remote control device 32 and thecharging station 50 is configured such that the second presence contact222 indicates the removal of the remote control device 32 from thecharging station 50, which ceases the transfer of power to therechargeable power source 180 from the charging station 50, before theat least one charging contact 210 is disengaged from the at least onecorresponding charging element 220. Hence, the transfer of power fromthe charging station 50 to the rechargeable power source 180 is ceasedbefore the at least one charging contact 210 is disengaged from the atleast one corresponding charging element 220. This may be effected, forexample, by setting the heights of the charging elements 220 and thesecond presence contact 222 as shown in FIG. 8A, wherein the chargingelements 220 are pushed down into respective element housings 220Abefore the second presence contact 222 engages the first presencecontact 212, as the remote control device 32 is inserted into thecharging station 50.

FIG. 15 is a block-level functional diagram of the portions 450 of theremote control device 32 that relate to recharging the rechargeablepower source 180. The other portions of the remote control device 32such as, for example, those that relate to the mechanical actuators arenot depicted in FIG. 15 . As noted above, the remote control device 32can include one or more charging contacts 210 that are configured toengage a corresponding charging element. In some embodiments, thecharging elements may be the charging elements 220 of the chargingstation 50. In other embodiments, the charging elements may be those ofan adapter that connects to a source of power to recharge therechargeable power source 180.

The remote control device 32 can include protection circuitry 452 thatlimits electrical parameters such as voltage and/or current to be withinexpected operating ranges. Charge controller and disconnect circuitry454 can monitor the voltage being received from the protection circuitry452 as well as monitor the present state of charge of the rechargeablepower source 180 in order to determine when to stop charging therechargeable power source 180. For example, according to one exemplaryembodiment, when the charge on the rechargeable power source 180 reaches3V, the charge controller and disconnect circuitry 454 can operate tostop further charging. The charge controller and disconnect circuitry454 can include temperature sensing capabilities or be connected to atemperature sensor so that the rechargeable power source 180 can becharged (or discharged) to different charging levels. In someembodiments, the rechargeable power source 180 is discharged to a hightemperature state of charge, e.g., a less than fully charged state, if asensed temperature is determined to be above a predetermined setpointtemperature. In one exemplary aspect of the invention, the sensedtemperature is an ambient temperature. In an alternative aspect, thesensed temperature is a battery temperature. In some embodiments, therechargeable power source 180 is charged at the charging station 50 to apredetermined charge level less than a 100% charge level if a sensedtemperature is determined to be above a predetermined thresholdtemperature. This may help prevent damage to or degradation of therechargeable power source 180.

As shown in FIG. 15 , the remote control device 32 can include thewireless communication system 456 such as, for example, a BLE radio thatcan communicate with the BLE radio 402 of the charging station 50 via aBLE connection. The wireless communication system 456 and/or the BLEradio 402 of the charging station 50 can be configured, for example, toenter a low power mode when the remote control device 32 is being pairedto the vehicle 10 and/or the rechargeable power source 180 of the remotecontrol device 32 is being charged at the charging station 50, e.g., toensure that only a remote control device 32 that is within a minimumdistance, for example, less than five inches or less than three inchescorresponding to the signal strength of the communications received fromthe remote control device 32, from the charging station 50 is recognizedas the remote control device 32 to pair with. Additionally, if the BLEradio 402 of the charging station 50 were to identify two or more remotecontrol devices 32 available for pairing and could not determine thecorrect one for pairing, the charging station 50 may not pair with anyof the available remote control devices 32 and may require the operatorto repeat the pairing process.

Associating/Pairing a Remote Control Device with a Vehicle

FIGS. 16-18 illustrate details of exemplary pairing processes inaccordance with aspects of the invention. The remote control device 32and vehicle 10 described above will be used in describing the pairingprocesses of FIGS. 16-18 , but it is understood that otherconfigurations/styles of the remote control device and vehicle could bepaired together in accordance with the invention.

With reference to FIG. 16 , the method 500 begins when the vehicleoperator retrieves a remote control device 32 at 502. If the remotecontrol device 32 is a wearable device as in the embodiments of FIGS.4-8 and 9-10 , the remote control device 32 is also donned by theoperator, e.g., by securing the holding strap 190 to the operator'sfinger(s).

The vehicle operator then initiates a power on sequence to enable thevehicle 10 for operation, i.e., the operator starts the vehicle 10 at504. In starting the vehicle 10, the operator may be required to providelogin information to the vehicle 10. This information may be providedfor, by example, entering a personal identification number (PIN) into acontrol panel of the vehicle 10, by utilizing a key fob to provide thelogon ID to the vehicle 10, or the operator's PIN may be encoded into amemory device, such as a radio-frequency identification (RFID) chip thatis integrated into the remote control device 32.

The operator then starts a pairing operation with the vehicle 10 at 506,and the pairing system 34 then pairs the remote control device 32 usedby the operator to the vehicle 10 at 508. Details of two exemplarypairing operations will be described in detail below with reference toFIGS. 17 and 18 .

Once paired, the system 8 may provide a visual indication as such, e.g.,by displaying a message on the vehicle 10, illuminating the LED 424 in apredetermined color, making an audible or visual queue, etc., thatindicates that the pairing is complete.

In accordance with an aspect of the invention, the remote control device32 may be unpaired from the vehicle 10 by powering down the vehicle 10.Other exemplary methods for unpairing the remote control device 32 fromthe vehicle 10 are described below in exemplary use cases.

The operation of two example pairing systems 34 are described inrelation to FIGS. 17 and 18 , respectively, which are flowcharts ofexample methods 550 and 600 for pairing a vehicle 10 and a remotecontrol device 32 using a pairing system 34 that is part of the chargingstation 50 on board the vehicle 10. The descriptions of the methods 550and 600 of FIGS. 17 and 18 begin as the remote control device 32 isinserted into the charging station 50, corresponding to step 506 of FIG.16 .

With reference to FIG. 17 and the method 550, at 552, when the secondpresence contact 222 is engaged by the first presence contact 212 as theremote control device 32 is inserted into the charging station 50, theBLE radio 402 of the charging station 50 is enabled so as to startscanning or listening for nearby BLE transmissions. As discussed above,the engagement of the second presence contact 222 by the first presencecontact 212 can also cause the current limiter 406 to be enabled so thatpower from the vehicle 10 can be provided to the charging contacts 210from the charging elements 220, which will cause the rechargeable powersource 180 of the remote control device 32 to be recharged. Accordingly,pairing and charging operations are initiated by the single action ofcoupling the remote control device 32 with the charging station 50. Inlieu of using BLE transmissions to pair the remote control device 32 tothe vehicle controller 103, the remote control device 32 can be pairedto the vehicle controller 103 by direct physical contact between, forexample, the charging contacts 210 and the charging elements 220.Alternatively, dedicated pairing contacts (not shown) may be provided onthe remote control device 32 and the vehicle 10, e.g., at the chargingstation 50, to pair the remote control device 32 to the vehiclecontroller 103 via direct physical contact. Such pairing contacts on theremote control device 32 and the vehicle 10 could be engaged with eachother concurrently with the engagement of the charging contacts 210 tothe charging elements 220, such that the pairing process could occur atthe same time as the charging process. These pairing contacts could beused solely for performing message exchanges for pairing operations.

According to one aspect of the invention, where the pairing process isaccomplished wirelessly, at 554, the remote control device 32 detectsthat a voltage is present at its charging contacts 210 and beginstransmitting BLE advertisements via the wireless transmitter 178indicating that the remote control device 32 is available forcommunicating with nearby devices.

In response, the BLE radio 402 of the charging station 50 can receiveone of the transmitted advertisements and, at 556, issue a BLE scanrequest directed to the specific remote control device 32 associatedwith the received advertisement. If the BLE radio 402 of the chargingstation 50 were to identify two or more remote control devices 32available for pairing, i.e., by receiving BLE advertisements from two ormore remote control devices 32 while scanning or listening for nearbyBLE transmissions, the vehicle 10 may not pair with any of the availableremote control devices 32 and may require the operator to repeat thepairing process by removing the remote control device 32 from thecharging station 50 and then reinserting the remote control device 32into the charging station 50.

At 558, the remote control device 32 responds to the scan request with aunique identification code, which the BLE radio 402 receives.

At 560, the vehicle 10 verifies the code and instructs the BLE radio 402to open a BLE connection and begin communicating with the remote controldevice 32.

At 562, once a communication session is established between the remotecontrol device 32 and the charging station 50, a predetermined pairingalgorithm can be implemented between the remote control device 32 andthe charging station 50 to complete the pairing operation at 564. Oncepaired, the vehicle 10 wirelessly communicates with the remote controldevice 32, and the controller 103 of the vehicle 10 is capable ofimplementing wireless requests received from the remote control device32.

In the example flowchart described above with respect to FIG. 17 , asimilar method can be performed to pair the remote control device 32 tothe vehicle 10 using, for example, one or more of the charging elements220 of the charging station 50 and the charging contacts 210 of theremote control device 32, or the dedicated pairing contacts noted above.Instead of the messages being transmitted and received via wireless/BLEradios, the same or equivalent types of messages can be communicatedthrough the elements/contacts 220/210 via various protocols. Themessages can be modulated and transmitted over one of theelements/contacts 220/210 providing the voltage. In either case, pairingof the vehicle 10 and the remote control device 32 can occurconcurrently with the charging of the rechargeable power source 180 ofthe remote control device 32.

With reference to FIG. 18 and the method 600, at 602, when the secondpresence contact 222 is engaged by the first presence contact 212 as theremote control device 32 is inserted into the charging station 50, theBLE radio 402 of the charging station 50 is enabled with apredetermined, e.g., 1500 ms, timeout so as to start scanning orlistening for nearby BLE transmissions from remote control devices 32.As discussed above, the engagement of the second presence contact 222 bythe first presence contact 212 can also cause the current limiter 406 tobe enabled so that power from the vehicle 10 can be provided to thecharging contacts 210 from the charging elements 220, which will causethe rechargeable power source 180 of the remote control device 32 to berecharged. Accordingly, pairing and charging operations are initiated bythe single action of coupling the remote control device 32 with thecharging station 50 such that a component of the remote control device32 physically contacts an element of the charging station 50. In lieu ofusing BLE transmissions to pair the remote control device 32 to thevehicle controller 103, the remote control device 32 can be paired tothe vehicle controller 103 by direct physical contact between, forexample, the charging contacts 210 and the charging elements 220.Alternatively, dedicated pairing contacts (not shown) may be provided onthe remote control device 32 and the vehicle 10, e.g., at the chargingstation 50, to pair the remote control device 32 to the vehiclecontroller 103 via direct physical contact. Such pairing contacts on theremote control device 32 and the vehicle 10 could be engaged with eachother concurrently with the engagement of the charging contacts 210 tothe charging elements 220, such that the pairing process could occur atthe same time as the charging process. These pairing contacts could beused solely for performing message exchanges for pairing operations.

At 604, the signal strength of the BLE transmissions between thewireless transmitter 178 and the BLE radio 402 may be decreased duringthe pairing process to help prevent any other nearby vehicles 10 fromreceiving the BLE transmissions from the remote control device 32.

According to one aspect of the invention, where the pairing process isaccomplished wirelessly, at 606, the remote control device 32 detectsthat a voltage is present at its charging contacts 210 and beginstransmitting BLE advertisements via the wireless transmitter 178 at apredetermined rate, e.g., a 20 ms rate with a predetermined timeout,e.g., 2000 ms timeout, indicating that the remote control device 32 isavailable for communicating with nearby vehicles 10. If the BLE radio402 of the charging station 50 were to identify two or more remotecontrol devices 32 available for pairing, i.e., by receiving BLEadvertisements from two or more remote control devices 32 while scanningor listening for nearby BLE transmissions, the vehicle 10 may not pairwith any of the available remote control devices 32 and may require theoperator to repeat the pairing process by removing the remote controldevice 32 from the charging station 50 and then reinserting the remotecontrol device 32 into the charging station 50.

The charging station 50 may provide power to charge the rechargeablepower source 180 for up to about, e.g., 1000 ms before the BLEadvertisements are sent from the wireless transmitter 178. Charging ofthe rechargeable power source 180 by the charging station 50 will bediscussed in detail below.

In response to receiving the BLE advertisements from the wirelesstransmitter 178, the BLE radio 402 of the charging station 50 can, at608, issue a BLE scan request.

At 610, the remote control device 32 receives the scan request from theBLE radio 402 and uses the address of the BLE radio 402 to create aunique identification code, which the remote control device 32 sendsback to the BLE radio 402 at 612.

At 614, the vehicle 10 verifies the code and instructs the BLE radio 402to open a BLE connection and begin communicating with the remote controldevice 32. It is noted that if the vehicle 10 receives more than onevalid identification code during step 614, for example, if the vehicle10 receives identification codes from two different remote controldevices 32, pairing will fail, the vehicle 10 may issue an error messageor other warning, and the operator will be required to repeat thepairing process by removing the remote control device 32 from thecharging station 50 and then reinserting the remote control device 32into the charging station 50.

At 616, once a communication session is established between the remotecontrol device 32 and the charging station 50, the pairing operation maybe completed, and the signal strength of the BLE transmissions betweenthe wireless transmitter 178 and the BLE radio 402 may be increased backto their normal levels at 618.

The operator may be required to perform an action at 620 as a test toconfirm that the remote control device 32 is functional and cancommunicate to the charging station 50, such as by pressing a buttonsequence on the remote control device 32, for example, by pressing thehorn button 197B and brake button 197C concurrently.

Once paired, the vehicle 10 wirelessly communicates with the remotecontrol device 32, and the controller 103 of the vehicle 10 is capableof implementing wireless requests received from the remote controldevice 32.

In accordance with aspects of the invention, a pairing period (which isa time period that it takes to establish communication between theremote control device 32 and the vehicle 10 and commences with steps552/602 and ends with steps 564/616) may be less than the chargingperiod (which is the time it takes to charge the rechargeable powersource 180 to a desired charge state at the charging station 50),wherein charging of the rechargeable power source 180 will be discussedbelow in connection with FIGS. 21 and 22 .

Referring to FIG. 19 , in accordance with an additional aspect of theinvention, after performing work operations, the vehicle operator mayneed to temporarily leave the vehicle 10, e.g., to take a break. Anexemplary method 700 is illustrated for shutting down, restarting andre-pairing the vehicle 10 to the remote control device 32 used by theoperator. The operator powers down the vehicle 10 at 702, so as to takea break, etc. After a time, the vehicle operator powers the vehicle 10back up. During this time of the break, the remote control device 32 maycontinue to be paired with the vehicle 10 for up to a predefined timeperiod. This state of maintained pairing between the vehicle 10 and theremote control device 32 may be indicated, for example, on a touchscreen(not shown) provided on the vehicle 10, by illuminating the LED 424 in apredetermined color, pattern, etc. Thus, if the operator powers thevehicle 10 back up before the predefined time period expires at 704, thevehicle 10 may detect the remote control device 32 at 706, wherein theremote control device 32 remains paired with the vehicle 10. In thisregard, the operator may or may not have to take some type of action at708, such as by pressing a button on the vehicle 10, e.g., on thecharging station 50, on the touchscreen, etc., or by pressing a buttonsequence on the remote control device 32.

A successful operator action at 708 results in a confirmation of thepairing between the remote control device 32 and the vehicle 10 at 710.A visual queue may be displayed on the indicator (the LED 424) tosignify the pairing, e.g., by illuminating the LED 424 in the secondcolor noted above.

Alternatively, according to this aspect of the invention, if theoperator powers the vehicle 10 back up after the predefined time periodexpires at 712, the operator may be required to re-pair the remotecontrol device 32 to the vehicle 10 as with the initial pairing, e.g.,by inserting the remote control device 32 into the charging station 50at 714.

With reference to FIG. 20 , an example method 800 is illustrated forreestablishing communication between the remote control device 32 andthe vehicle 10 after a period of no vehicle-related activity has beenperformed. At 802, the controller 103 on the vehicle 10 detects that novehicle-related activity has been performed for a given period of timeafter communication between the remote control device 32 and the vehicle10 has been established. Exemplary vehicle-related activities includedriving the vehicle 10 (either manually using the manual controls in theoperator's station 20, other manual controls, e.g., on the side of thevehicle 10, or via the remote control device 32), standing on theplatform 21, moving or placing an item on the load handling assembly 12,etc. At 804, if no vehicle-related activity takes place for greater thana first predetermined amount of time after communication between theremote control device 32 and the vehicle 10 is established, thecommunication between the remote control device 32 and the vehicle 10 isterminated and must be re-established using the pairing system 34 at806, i.e., by inserting the remote control device 32 into the chargingstation 50 at the vehicle 10. This state of terminated pairing betweenthe vehicle 10 and the remote control device 32 may be indicated, forexample, on the touchscreen, by illuminating the LED 424 in apredetermined color, pattern, etc.

At 808, if no vehicle-related activity takes place for less than asecond predetermined amount of time after communication between theremote control device 32 and the vehicle 10 is established, the secondpredetermined amount of time equal to or less than the firstpredetermined amount of time, the communication between the remotecontrol device 32 and the vehicle 10 is terminated but can bere-established without the pairing system 34, e.g., by performing aconfirmation method utilizing the remote control device 32 at 810. Theconfirmation method may comprise, for example, the operator carrying outa button sequence on the remote control device 32, such as bylong-pressing one or more of the buttons 197A-C. This state of pairingbetween the vehicle 10 and the remote control device 32 may beindicated, for example, on the touchscreen, by illuminating the LED 424in a predetermined color, pattern, etc.

FIG. 21 is a flowchart of an example method 900 for charging a remotecontrol device in accordance with the principles of the presentinvention. In particular, the remote control device may be the same asor similar to the remote control device 32 discussed herein, and caninclude a wireless communication system 456 including a wirelesstransmitter 178 (e.g., capable of one or two-way communication), arechargeable power source 180, and at least one control (e.g., controls196A-C) that causes the wireless transmitter 178 to wirelessly transmita request to a controller of a materials handling vehicle 10.

The method 900 for charging a remote control device 32 begins at 902 byinitiating contact between a component of the remote control device 32and an element of a charging station 50, the charging station 50 locatedat the vehicle 10, and then sensing contact between the remote controldevice component and the charging station element. As described above,the remote control device 32 can include one or more charging contacts210 that are each arranged to engage a corresponding charging element220 of the charging station 50, such that when they are engaged, asecond presence contact 222 or a similar device engages a correspondingfirst presence contact 212 to detect or sense that the chargingcontact(s) 210 and charging element(s) 220 are in contact with oneanother. However, other components of the remote control device 32 andother elements of the charging station 50 may be used to detect/sensethe initiation of contact.

Next, at 904, a charging period is started, wherein power is suppliedfrom the charging station 50 to the rechargeable power source 180. Asdescribed above, as an example, circuitry of the charging station 50 isconfigured such that upon the sensing of contact between the chargingcontact(s) 210 and charging element(s) 220, power is supplied from thecharging station 50 to the charging contacts 210 of the remote controldevice 32 to charge the rechargeable power source 180. Once therechargeable power source 180 is substantially fully charged (or chargedto the desired amount less than a substantially full state of charge),the remote control device 32 can be removed from the charging station50.

Thus, the method of FIG. 21 continues, at 906, with interrupting contactbetween the remote control device component and the charging stationelement, and sensing the interruption of the contact between the remotecontrol device component and the charging station element. As describedabove, the charging contact(s) 210 of the remote control device 32 andthe charging element(s) 220 of the charging station 50 are arranged suchthat as the two systems are disengaged, that state can be detected orsensed. One example is the second presence contact 222 that can detectwhen the remote control device 32 is being removed from the chargingstation 50.

Finally, upon the sensing of this interruption at 906, the chargingstation 50 can cease the supply of power from the charging station 50 tothe rechargeable power source 180 at 908, thus ending the chargingperiod. It is noted that the second presence contact 222 can be locatedon the remote control device 32 and its disengagement can result inceasing the supply of power from the charging station 50 to therechargeable power source 180. The supply of power from the chargingstation 50 to the rechargeable power source 180 may also be ceased whenthe rechargeable power source 180 is charged up to the desired amount(either fully charged or charged up to a desired amount less than fullycharged), as described herein.

The method 900 can include other optional steps shown in FIG. 21 . Forexample, the method 900 can also include confirming the establishment ofcommunication between the remote control device 32 and the vehicle 10 at910, e.g., with at least one of an audible or visual queue. The method900 can further include, while the remote control device component is incontact with the charging station element, establishing communicationbetween the remote control device 32 and the vehicle 10 (e.g., pairing)during a pairing period at 912, such that the controller 103 receivestransmissions from the remote control device 32 and is capable ofimplementing wireless requests from the remote control device 32. Thiscommunication between the remote control device 32 and the vehicle 10can be established concurrently during charging of the rechargeablepower source 180 at the charging station 50, such that the pairingperiod and the charging period overlap. In at least some embodiments thepairing period is less than or equal to the charging period.

Additionally, the method 900 may include, at 914, displaying a state ofcharge of the rechargeable power source 180 at the vehicle 10, e.g., atthe charging station 50, wherein the state of charge of the rechargeablepower source 180 may be displayed at the vehicle 10 both when chargingthe rechargeable power source 180 and during use of the remote controldevice 32. The state of charge of the rechargeable power source 180 maybe displayed, for example, via a series of lights, each lightrepresenting a level of a state of charge of the rechargeable powersource 180.

FIG. 22 is a flowchart of another example method 950 for charging aremote control device in accordance with the principles of the presentinvention, such as the remote control device 32 discussed herein, whichcomprises a wireless communication system 456 including a wirelesstransmitter 178 (e.g., capable of one or two-way communication), arechargeable power source 180, and at least one control (e.g., controls196A-C) that causes the wireless transmitter 178 to wirelessly transmita request to a controller of a materials handling vehicle 10. As usedherein, the term “control”, when used to describe a control of theremote control device 32, is meant to include any structure capable ofproviding the desired function, including but not limited to buttons,switches, dials, etc.

The method 950 for charging a remote control device 32 begins at 952 byinitiating contact between a component of the remote control device 32and an element of a charging station 50, the charging station 50 locatedat the vehicle 10, and then sensing contact between the remote controldevice component and the charging station element. As described above,the remote control device 32 can include one or more charging contacts210 that are each arranged to engage a corresponding charging element220 of the charging station 50, such that when they are engaged, asecond presence contact 222 or a similar device engages a correspondingpresence contact 212 to detect or sense that the charging contact(s) 210and charging element(s) 220 are in contact with one another. However,other components of the remote control device 32 and other elements ofthe charging station 50 may be used to detect/sense the initiation ofcontact.

At 954, the current state of charge of the rechargeable power source 180is determined. Step 954 can be performed before or after step 952, i.e.,the state of charge of the rechargeable power source 180 may becommunicated to the charging station 50 both when the remote controldevice 32 is coupled to the charging station 50, and during use of theremote control device 32 by the operator, as discussed herein.

Based on the current state of charge of the rechargeable power source180 and after step 952 is performed, at 956, a charging period isstarted, wherein power is supplied from the charging station 50 to therechargeable power source 180. In one exemplary embodiment, at step958A, if the voltage of the rechargeable power source 180 is below avoltage threshold VT, the charging station 50 charges the rechargeablepower source 180 at a first, higher power level PL1. According to thisembodiment, at step 958B, if the voltage of the rechargeable powersource 180 is above the voltage threshold VT, the charging station 50charges the rechargeable power source 180 at a second, lower power levelPL2. The resulting charging period in either case, i.e., at step 958A orstep 958B, may be about the same, i.e., charging the rechargeable powersource 180 up to the desired amount from above or below the voltagethreshold VT may take about the same time. While only two power levelsPL1, PL2 associated with a single voltage threshold VT are discussedherein, additional voltage thresholds and power levels could be used,wherein the charging period can always be about the same time,regardless of the charge level of the rechargeable power source 180 whenit is inserted into the charging station 50. Additionally, an equationcould be used to dynamically set the power level according to thecurrent state of charge of the rechargeable power source 180.

Once the charging period is complete, that is, once the rechargeablepower source 180 is charged to the desired amount, i.e., substantiallyfully charged or charged to an amount less than a substantially fullstate of charge, e.g., in view of the sensed temperature if thattechnology is present in the system 8, or if less than a full charge isdesired, the remote control device 32 can be removed from the chargingstation 50.

Thus, the method of FIG. 22 continues, at 960, with interrupting contactbetween the remote control device component and the charging stationelement, and sensing the interruption of the contact between the remotecontrol device component and the charging station element. As describedabove, the charging contact(s) 210 of the remote control device 32 andthe charging element(s) 220 of the charging station 50 are arranged suchthat as the two systems are disengaged, that state can be detected orsensed. One example is the second presence contact 222 that can detectwhen the remote control device 32 is being removed from the chargingstation 50.

Finally, upon the sensing of this interruption at 960, or upon therechargeable power source 180 being charged to the desired amount, thecharging station 50 can cease the supply of power from the chargingstation 50 to the rechargeable power source 180 at 962, thus ending thecharging period.

The method 950 can include other optional steps shown in FIG. 22 . Forexample, the method 950 can also include confirming the establishment ofcommunication between the remote control device 32 and vehicle 10 at964, e.g., with at least one of an audible or visual queue. The method950 can further include, while the remote control device component is incontact with the charging station element, establishing communicationbetween the remote control device 32 and the vehicle 10 (e.g., pairing)during a pairing period at 966, such that the controller 103 receivestransmissions from the remote control device 32 and is capable ofimplementing wireless requests from the remote control device 32. Thiscommunication between the remote control device 32 and the vehicle 10can be established concurrently during charging of the rechargeablepower source 180 at the charging station 50, such that the pairingperiod and the charging period overlap. In at least some embodiments,the pairing period is less than or equal to the charging period,although the pairing period may be greater than the charging period, aswill be discussed in more detail below.

Additionally, the method 950 may include, at 968, displaying a state ofcharge of the rechargeable power source 180 at the vehicle 10, e.g., atthe charging station 50, wherein the state of charge of the rechargeablepower source 180 may be displayed at the vehicle 10 both when chargingthe rechargeable power source 180 and during use of the remote controldevice 32. The state of charge of the rechargeable power source 180 maybe displayed, for example, via a series of lights, each lightrepresenting a level of a state of charge of the rechargeable powersource 180.

In accordance with an aspect of the invention, the charging period maydepend on the capacity of the rechargeable power source 180, the chargerate/power level supplied by the charging station 50, and/or the chargestate of the rechargeable power source 180 when it is inserted into thecharging station 50. Thus, a desired charging period could be achievedregardless of the current state of charge of the rechargeable powersource 180 when the remote control device 32 is placed in the chargingstation 50. For example, the current state of charge of the rechargeablepower source 180 may be known to the vehicle 10, e.g., the state ofcharge of the rechargeable power source 180 may be communicated to thecharging station 50, as discussed herein. The charging station 50 may beinstructed, e.g., by the controller 103, to supply power to therechargeable power source 180 at different rates or levels based on thestate of charge of the rechargeable power source 180 when the remotecontrol device 32 is placed in the charging station 50, so that thecharging period is generally about the same time regardless of the stateof charge of the rechargeable power source 180 when the remote controldevice 32 is placed in the charging station 50. For example, asdiscussed above with reference to steps 958A/B of FIG. 22 , if the stateof charge of the rechargeable power source 180 is a first, lower stateof charge, then a first, greater rate/level of power may be suppliedfrom the charging station 50 to the rechargeable power source 180. Ifthe state of charge of the rechargeable power source 180 is a second,higher state of charge, then a second, lesser rate/level of power may besupplied from the charging station 50 to the rechargeable power source180. The resulting charging period in both cases could be about the sametime, e.g., within about 0.5 seconds of the desired charging period. Anynumber of rechargeable power source states of charge and correspondingrates/levels of power could be implemented such that the time requiredto charge the rechargeable power source 180 is within the desiredcharging period. Additionally, the usage life of the rechargeable powersource 180 may be increased when it is charged at a lower power level.Hence, an additional advantage of a consistent charging period as withthe present invention is that the rechargeable power source 180 issometimes charged at a lower power level, e.g., when the charge state ofthe rechargeable power source 180, when it is inserted into the chargingstation 50 is the second, higher state of charge discussed above. Hence,charging the rechargeable power source 180 at different power levels asdiscussed herein may increase the usage life of the rechargeable powersource 180, as opposed to if the rechargeable power source 180 wascharged at a consistent, higher power level with each charge.

Additionally, while the pairing period, which is described herein as thetime period it takes to establish communication between the remotecontrol device 32 and the vehicle 10, may be less than or equal to thecharging period, the charging period may also be less than the pairingperiod. As one example, it may be determined that the rechargeable powersource 180 does not need to be fully charged in order to operate for adesired use period. For example, a full charge of the rechargeable powersource 180 may provide an operation time that is greater than a desireduse period (e.g., an operator's shift), such that the rechargeable powersource 180 does not need to be fully charged in order to be operable forthe desired use period. In this case, the charging station 50 may beprogrammed to charge the rechargeable power source 180 up to a less thanfull state of charge, which would still be sufficient for the remotecontrol device to be operable for the entire desired use period. Thetime it takes to charge rechargeable power source 180 up to this lessthan full state of charge may be less than the pairing period. Othersituations may also occur where the charging period may be less than thepairing period.

With reference to FIG. 23 , the principles of the present invention canalso be implemented as a kit 1000 for retrofitting to a materialshandling vehicle 10′. In FIG. 23 , elements similar to or identical tothose described above with reference to FIGS. 1-22 include the samereference number followed by a prime symbol (′). An element describedwith respect to FIG. 23 but not specifically shown in FIG. 23 isequivalent to the element having the same reference symbol as describedabove, but without the prime symbol.

The vehicle 10′ can include a vehicle controller 103′ that is responsiveto wireless requests from an associated remote control device 32′ thatis used by an operator interacting with the vehicle 10′ similar to thosetypes of vehicles 10 and remote control devices 32 described above. Anexample kit 1000 would include a charging station 50′ at the vehicle10′, the charging station 50′ for charging a rechargeable power source180′ of the remote control device 32′, wherein the charging station 50′is electrically coupled to a vehicle power source, and a receiver 102′such as a BLE radio communicably coupled to the controller 103′ of thevehicle 10′. In particular, the charging station 50′ is configured suchthat the rechargeable power source 180′ is charged up to a desiredamount (a full charge or less than full charge as discussed herein) atthe charging station 50′ within a desired charging period.

The kit 1000 may further include a pairing system 34′ for establishingcommunication between the remote control device 32′ and the vehicle 10′,such that the controller 103′ is capable of implementing wirelessrequests from the remote control device 32′. The pairing system 34′ may,for example, be similar to pairing system 34 and can implement thepairing algorithm(s) detailed in FIG. 17 and/or FIG. 18 . Thus, the kit1000 can also include a pairing indicator, e.g., visual indicator 424′,that confirms the establishment of communication between the remotecontrol device 32′ and the vehicle 10′. Furthermore, the pairing system34′ can be configured such that the pairing period (a time period thatit takes to establish communication between the remote control device32′ and the vehicle 10′) may be less than or equal to the chargingperiod (a time period it takes to charge the rechargeable power source180′ to the desired amount). The pairing period may also be greater thanthe charging period. The pairing system 34′ may be incorporated into thecharging station 50′ or may be a separate element.

It is contemplated that communication between the remote control device32′ and the vehicle 10′ is established concurrently during charging ofthe rechargeable power source 180′ at the charging station 50′, i.e.,the pairing period and the charging period may overlap. Furthermore, insome embodiments, communication between the remote control device 32′and the vehicle 10′, and charging of the rechargeable power source 180′at the charging station 50′ are initiated with a single action. Forexample, the single action can comprise physically contacting acomponent of the remote control device, for example, one or morecharging contacts 210 as described above, with an element of thecharging station, for example, one or more corresponding chargingelements 220 as described above.

The remote control device 32′ used in combination with the kit 1000 maybe the same as the remote control devices 32 disclosed herein. Hence, aremote control device manufactured for use with a vehicle 10 includingan integrated charging station 50 and related components could also beused with a kit 1000 for use with an existing vehicle 10′.

As described above with respect to the charging station 50, the chargingstation 50′ of the kit 1000 can also include guide structure 420′ toalign the remote control device 32′ in the proper orientation forcharging the rechargeable power source 180′.

The kit 1000 can also include an indicator (e.g., LEDs 404′, light, orsimilar structure) configurable to be attachable at the vehicle 10′ forindicating a state of charge of the rechargeable power source 180′. Theindicator can indicate the state of charge of the rechargeable powersource 180′ both when charging the rechargeable power source 180′ at thecharging station 50′ and during use of the remote control device 32′. Insome embodiments, the indicator comprises a series of lights, each lightrepresenting a level of the state of charge of the rechargeable powersource 180′.

The kit 1000 includes at least one charging element 220′ on the chargingstation 50′ that engages at least one corresponding charging contact210′ of the remote control device 32′. Furthermore, at least one of theremote control device 32′ or the charging station 50′ includes apresence contact 212′ or 222′ that detects whether or not at least onecorresponding charging contact 210′ and at least one charging element220′ are correctly engaged with one another. If a correct engagement isdetected, the transfer of power to the rechargeable power source 180′ ofthe remote control device 32′ is enabled by the charging station 50′,and if a correct engagement is not detected, the transfer of power tothe rechargeable power source 180′ is not enabled by the chargingstation 50′. In at least some embodiments, the remote control device 32′comprises at least two charging contacts 210′ or at least four chargingcontacts 210′ that are positioned to engage corresponding chargingelements 220′ on the charging station 50′.

The arrangement of the remote control device 32′ and the chargingstation 50′ of the kit 1000 is configured such that the presence contact212′ or 222′ indicates the removal of the remote control device 32′ fromthe charging station 50′, which ceases the transfer of power to therechargeable power source 180′ from the charging station 50′, before theat least one charging contact 210′ is disengaged from the at least onecorresponding charging element 220′. Hence, the transfer of power fromthe charging station 50′ to the rechargeable power source 180′ is ceasedbefore the at least one charging contact 210′ is disengaged from the atleast one corresponding charging element 220′.

The kit 1000 may also utilize contactless, or induction, charging inwhich the rechargeable power source 180′ of the remote control device32′ can be charged by being in close proximity to, or on the surface of,a compatible induction charging station (not shown). Such an inductioncharging station may be located, for example, in a driving or steeringcontrol of the vehicle 10′ such that the rechargeable power source 180′may be charged while the operator is manually driving the vehicle 10′from the operator's station 20′. The kit 1000 according to this aspectof the invention may be at least partially located in the vehiclesteering control or other vehicle component that facilitates thecontactless/induction charging of rechargeable power source 180′, e.g.,the rechargeable power source 180′ may be charged by the operatorgrasping the driving/steering control.

The kit 1000 may utilize any of the other features and/or functions ofthe remote control device 32′ and the charging station 50′ describedabove for FIGS. 1-22 . It is noted that if the vehicle 10′ to be usedwith the kit 1000 was previously set up for interacting with a wirelessremote control device, the controller logic in the vehicle controller103′ may need to be updated to be used with the kit 1000, and a receiverthat was already provided at the vehicle 10′, i.e., for receivingwireless requests from a remote control device that was used with thevehicle 10′ before the kit 1000 was installed on the vehicle 10′, may beturned off in lieu of the receiver 102′ of the kit 1000, i.e., for usewith the remote control device 32′ associated with the kit 1000.

With reference now to FIG. 24 , a remote control device 32 in accordancewith an embodiment of the invention may be incorporated into a glovegarment 1100. The use of the glove garment 1100 eliminates the need forthe holding strap 190, and the first control 196A may be provided on afinger of the glove garment 1100 as opposed to being a part of the upperhousing 174, but the remaining components of the remote control device32 illustrated in FIG. 24 may be the same or similar to those of theremote control device 32 of FIGS. 4-7 , including a shape of the portionof the upper housing 174 that engages with the charging station 50 atthe vehicle 10. Hence, the charging station 50 at the vehicle 10 may bethe same as the charging station 50 described above, i.e., since thecharging station-engaging portion of the upper housing 174 of the remotecontrol device 32 incorporated into the glove garment 1100 can have thesame dimensions as the charging station-engaging portion of the upperhousing 174 of the remote control device 32 in the embodiment of FIGS.4-7 , the same charging station 50 could be used with either thefinger-mounted remote control device 32 of FIGS. 4-7 , or the remotecontrol device 32 incorporated into the glove garment 1100 of FIG. 24 .

If the remote control device 32 incorporated into the glove garment 1100were used in combination with the inductive charging technologydisclosed herein, inductive charging structures may be incorporated, forexample, into the palm of the glove garment 1100. Such chargingstructures in the glove garment 1100 could be used with chargingelements incorporated, for example, into a steering control of a vehiclepaired to the remote control device 32, in which case a rechargeablepower source of the remote control device 32 could be charged while theoperator is grasping the steering control.

According to additional aspects of the present invention, there may beconditions and/or events that cause the vehicle 10 to become unpairedfrom the remote control device 32, wherein a complete pairing processutilizing the pairing system 34, as described herein, may be required tore-pair the vehicle 10 with the remote control device 32. There may beother conditions or events that cause the vehicle 10 to become unpairedfrom the remote control device 32, wherein something other than acomplete pairing process utilizing the pairing system 34, as describedherein, may be required to re-pair the vehicle 10 with the remotecontrol device 32. Several exemplary use cases with regard to unpairingand re-pairing will now be described.

A first exemplary use case may occur by powering down the vehicle 10.According to this first use case, the remote control device 32 isunpaired from the controller 103 and requires a complete pairing processutilizing the pairing system 34, as described herein, to re-pair thevehicle 10 with the remote control device 32. In accordance with thisexemplary first use case, a complete pairing process utilizing thepairing system 34 may be required to re-pair the remote control device32 to the vehicle 10 whenever the vehicle 10 is powered down.

A second exemplary use case may be substantially as described above withrespect to FIG. 19 , wherein the vehicle operator temporarily leaves thevehicle 10, e.g., to take a break. The details of this second exemplaryuse case are discussed above with reference to FIG. 17 and will not berepeated again.

Third and fourth exemplary use cases may occur if no vehicle-relatedactivity takes place for greater than a first predetermined amount oftime after communication between the remote control device 32 and thevehicle 10 is established (third use case) or if no vehicle-relatedactivity takes place for less than a second predetermined amount of timeafter communication between the remote control device 32 and the vehicle10 is established (fourth use case). The details of these third andfourth exemplary use cases are discussed above with reference to FIG. 20and will not be repeated again.

A number of exemplary use cases may arise where multiple remote controldevices 32 and/or multiple vehicles 10 are concerned. In a fifthexemplary use case, assume a first remote control device 32 is currentlypaired with a first vehicle 10, and a second remote control device 32 iscurrently paired with a second vehicle 10. In this fifth use case, thefirst remote control device 32 is inserted into the charging station 50of the second vehicle 10. Under this circumstance, the charging station50 of the second vehicle 10 may charge the rechargeable power source 180of the first remote control device 32, the first remote control device32 may become unpaired from the first vehicle 10, and the second remotecontrol device 32 may become unpaired from the second vehicle 10. Thefirst remote control device 32 will not be paired to the second vehicle10 in the fifth use case.

In a sixth exemplary use case and with reference to FIG. 24 , assume aremote control device 32 is currently paired with a first vehicle 10Asuch that the remote control device 32 wirelessly communicates with thefirst vehicle 10A, and a second vehicle 10B is not currently paired witha remote control device. In this sixth use case, the remote controldevice 32 is paired with the second vehicle 10B using a pairing process,for example, by inserting the remote control device 32 into the chargingstation 50 of the second vehicle 10B. Using this pairing process, thecharging station 50 of the second vehicle 10B may charge therechargeable power source 180 of the remote control device 32, and theremote control device 32 may become paired with the second vehicle 10Bsuch that the remote control device wirelessly communicates with thesecond vehicle 10B. This pairing process may also cause the remotecontrol device to become unpaired from the first vehicle 10A, such thatthe remote control device no longer wirelessly communicates with thefirst vehicle 10A. Once the remote control device 32 is paired with thesecond vehicle 10B and unpaired from the first vehicle 10A, the secondvehicle 10B may respond to remote requests from the remote controldevice 32, while the first vehicle 10A may no longer respond to remoterequests from the remote control device 32.

As described above, the wireless communication system 456 of the remotecontrol device 32 and/or the BLE radio 402 of the charging station 50can be configured, for example, to enter a low power mode when theremote control device 32 is being paired to the second vehicle 10Band/or the rechargeable power source 180 of the remote control device 32is being charged at the charging station 50, e.g., to ensure that only aremote control device 32 that is within a minimum distance,corresponding to the signal strength of the communications received fromthe remote control device 32, from the charging station 50, isrecognized as the remote control device 32 for the second vehicle 10B topair with.

According to the sixth exemplary use case, prior to the pairing process,the second vehicle 10B may be sent, e.g., by a Warehouse ManagementSystem WMS in communication with the second vehicle 10B, to a designatedlocation, such as, for example, the location of the operator, thelocation of the first vehicle 10A, the end of an aisle in which theoperator and/or first vehicle 10A are located, a designated waitingarea, etc. The second vehicle 10B may be an unloaded vehicle, i.e., freefrom a load and thus ready to carry items to be picked by the operator.The second vehicle 10B may be instructed to move to the designatedlocation by the Warehouse Management System WMS, for example, when thefirst vehicle 10A is loaded with a desired amount of pick items and isready to be sent to a different location, i.e., a location that isdifferent than the current location of the vehicle 10, such as a loadingdock LD or other location where the pick items on the first vehicle 10Aare to be sent. The operator may also request that the second vehicle10B be sent to the designated location, for example, using a control onthe first vehicle 10A, over a headset, etc. Once the second vehicle 10Bis paired to the remote control device 32, the second vehicle 10B may nolonger implement commands from the Warehouse Management System WMS, suchthat the second vehicle 10B will only implement wireless commands fromthe remote control device 32 with which it is paired.

Once the remote control device 32 is unpaired from the first vehicle10A, the Warehouse Management System WMS may send instructions to thefirst vehicle 10A to move to the loading dock LD and/or to anotherlocation, such as a vehicle charging station (not shown). Using thissixth exemplary use case, an operator may quickly switch betweenvehicles 10A, 10B, resulting in an increase in work productivity andefficiency.

In a seventh exemplary use case, assume a first remote control device 32is currently paired with a vehicle 10, and a second remote controldevice 32 is not paired with a vehicle. In this seventh use case, thesecond remote control device 32 is inserted into the charging station 50of the vehicle 10. Under this circumstance, the charging station 50 ofthe vehicle 10 may charge the rechargeable power source 180 of thesecond remote control device 32, the first remote control device 32 maybecome unpaired from the vehicle 10, and the second remote controldevice 32 will not be paired to the vehicle 10.

In an eighth exemplary use case, the remote control device 32 is movedout of range of the vehicle 10, i.e., such that the wireless transmitter178 is no longer able to communicate with the receiver 102 for apredetermined time period. According to the eighth use case, the remotecontrol device 32 may become unpaired from the vehicle 10. According tothe eighth use case, if the remote control device 32 moves back intorange of the vehicle 10 after a predetermined time period, the vehicle10 may need to be shut down and restarted to pair with a remote controldevice 32 utilizing the pairing system 34, including pairing with thepreviously-paired remote control device 32, or a different remotecontrol device 32. If the remote control device 32 moves back into rangeof the vehicle 10 within the predetermined time period, the vehicle 10may not need to be shut down and restarted to pair with the previouslypaired remote control device 32, e.g., the previously paired remotecontrol device 32 may be re-paired with the vehicle 10 by inserting theremote control device 32 into the charging station 50 of the vehicle.Pairing the vehicle 10 to a different remote control device 32 mayrequire a vehicle shut down and restart, regardless of how long thepreviously paired remote control device 32 was out of range of thevehicle 10.

Additional exemplary use cases concerning pairing and/or chargingperiods will now be described.

In a ninth exemplary use case, a desired charge state, e.g., asubstantially full charge state, of the rechargeable power source 180can be achieved by charging the rechargeable power source 180 at thecharging station 50 in five seconds or less. According to this use case,the substantially full charge state of the rechargeable power source 180may yield a use period of the remote control device 32 of at least eighthours.

In a tenth exemplary use case, the charging station 50 varies the powerlevel supplied to the rechargeable power source 180 depending on thestate of charge of the rechargeable power source 180 when the remotecontrol device 32 is inserted into the charging station 50, as describedherein with respect to FIG. 22 . A charging period according to thetenth use case will always be about four seconds, regardless of thestate of charge of the rechargeable power source 180 when the remotecontrol device 32 is inserted into the charging station 50. Hence, apredictable charging period is achieved.

It is noted that the type of transmissions sent by the remote controldevice 32 to the vehicle 10, e.g., requests, such as travel requests,may be other types of transmissions. As one example, the transmissionsmay comprise location-based transmissions that inform the controller 103of the vehicle 10 where the remote control device 32 is located relativeto the vehicle 10. These types of location transmissions may be used bythe controller 103, e.g., to follow the remote control device 32. Hence,the vehicle 10 may follow an operator wearing, holding, or carrying theremote control device 32. Such a remote control device 32 could becharged by the charging station 50 and paired to the vehicle 10 asdescribed herein.

In accordance with another aspect of the present invention, charging ofthe rechargeable power source 180 by the charging station 50 may bedisabled while the vehicle 10 is in motion. This aspect of the inventionmay not apply to inductive charging of the rechargeable power source180.

Furthermore, when an operator is attempting to pair a remote controldevice 32 to a vehicle 10 that is in communication with the WarehouseManagement System WMS, the Warehouse Management System WMS can determineif one or more remote control device operational checks have beenperformed within a predetermined time period, for example, within thelast 12 hours. Such operational checks may include, for example, checksto ensure the operability of controls of the remote control device 32,such as the horn and/or brake buttons 197B, 197C. If such operationalcheck(s) have not been performed within the predetermined time period,the vehicle 10 may communicate to the operator that operational check(s)must be performed prior to the remote control device 32 being pairablewith the vehicle 10, i.e., the remote control device 32 is only allowedto pair with the vehicle 10 if the one or more remote control deviceoperational checks have been performed within the predetermined timeperiod. The operational checks may be performed by the operatorimplementing the controls, e.g., by holding down the horn and/or brakebuttons 197B, 197C.

Additionally, when an operator is attempting to pair a remote controldevice 32 to a vehicle 10 that is in communication with the WarehouseManagement System WMS, the Warehouse Management System WMS can determineif the operator is authorized to operate the vehicle 10 that theoperator is attempting to pair to the remote control device 32. Forexample, vehicles that are to be used only in a certain location, suchas in a freezer, may only be pairable with remote control devices 32where the operator will use the vehicle in that location. As anotherexample, operators may be limited to operating certain vehicles. Remotecontrol devices 32 in these situations may only be authorized to pairwith such vehicles when these condition(s) are met.

In accordance with an aspect of the invention, the charge life of therechargeable power source 180 over a given operating cycle may beincreased by turning off or reducing the power consumption of one ormore components of the remote control device 32, e.g., the components ofthe wireless communication system 456 including the wireless transmitter178, when an operator is determined to be standing on the platform 21 ofthe vehicle 10, e.g., as detected by the presence sensors 22.

The terms “pairing” and “synchronizing” (as used herein and in thevarious patents and published patent applications incorporated byreference herein) are used interchangeably herein to describe a secureprocess whereby a wireless remote control device and vehicle controlleridentify each other as valid command and response devices.

A charging station 1050 and a remote control device 1032 constructed inaccordance with a still further aspect of the present disclosure areillustrated in FIGS. 26 and 27 . Elements on the charging station 1050which are generally the same as elements on the charging station 50described above are referenced with the same reference numerals used forthose elements on the charging station 50. Similarly, elements on theremote control device 1032 which are generally the same as elements onthe remote control device 32 described above are referenced with thesame reference numerals used for those elements on the remote controldevice 32.

The charging station 1050 comprises a docking port 1052, which maycomprise a pocket or recess shaped to receive the remote control device1032 such that charging contacts 210 on the remote control device 1032are aligned with and engage with charging elements 220 at the chargingstation 1050 to effect charging of a rechargeable power source 180forming part of the remote control device 1032. It is also contemplatedthat the remote control device 1032 may also interact with the dockingport 1052 to allow charging of the rechargeable power source 180 via anon-contact charging operation, e.g., inductive charging.

The charging station 1050 can comprise one or more visual indicatorsthat convey information to an operator, which information may compriseone or more of: a charging state of the rechargeable power source 180when the remote control device 1032 is coupled to the charging station1050, a charging state of the rechargeable power source 180 when theremote control device 1032 is removed from the charging station 1050, apairing status between the wearable remote control device 1032 and thevehicle controller 103, and/or that the remote control device 1032 isphysically connected to the charging station 1050.

In the embodiment illustrated in FIGS. 26 and 27 , a first visualindicator 1060 and a second visual indicator 1070 are provided on thecharging station 1050. The first visual indicator 1060 may comprise oneor more lights, such as LEDs. The first visual indicator 1060 may beprovided proximate to the docking port 1052 defined within the chargingstation 1050, as viewed in FIGS. 26 and 27 , which docking port 1052, asnoted above, comprises a pocket or recess shaped to receive the remotecontrol device 1032. A graphic 1034 may be provided on the remotecontrol device 1032 adjacent to a travel button 197A also provided onthe remote control device 1032, see FIG. 26 , which travel button 197Amay cause a wireless transmitter 178 forming part of the remote controldevice 1032 to wirelessly transmit a request for a vehicle 10 to travelacross a floor surface. The first visual indicator 1060 may be shaped tocorrespond to the graphic 1034 provided on the remote control device1032 to aid a user in positioning and connecting the remote controldevice 1032 to the docking port 1052 of the charging station 1050. Inthe illustrated embodiment, the graphic 1034 provided on the remotecontrol device 1032 is shaped as an isosceles triangle facing upwardwhen the remote control device 1032 is coupled to the charging station1050, but could comprise any other geometric shape, image, icon, etc.Also in the illustrated embodiment, the first visual indicator 1060 isgenerally shaped as an isosceles triangle pointing downward, but couldcomprise any other geometric shape, image, icon, etc. The first visualindicator 1060 shaped as a downward facing triangle provides anindication to a user that the remote control device 1032 should bepositioned relative to the docking port 1052 such that the upward facingtriangle 1034 on the remote control device 1032 is positioned adjacentto the first visual indicator 1060 so as to mate with or mirror thefirst visual indicator 1060.

The second visual indicator 1070 may be positioned proximate to thefirst visual indicator 1060, such as just above the first visualindicator 1060 as viewed in FIGS. 26 and 27 . The second visualindicator 1070 may be defined by a plurality of linearly arrangedlights, such as LEDs, which may be activated individually and serially.The lights of the second visual indicator 1070 may have a differentcolor than the one or more lights of the first visual indicator 1060.

When a vehicle 10 comprising the charging station 1050 is powered up,i.e., turned from an OFF state to an ON state, the first visualindicator 1060 may be activated and, preferably, is pulsed ON and OFF toprovide a visual display related to inserting the wearable remotecontrol device 1032 into the docking port 1052, while the second visualindicator 1070 remains OFF, see FIG. 28A. With the first visualindicator 1060 activated, i.e., pulsed ON and OFF, and the second visualindicator 1070 OFF, this indicates to an operator that the chargingstation 1050 is enabled and functional and she/he needs to couple theremote control device 1032 to the docking port 1052 of the chargingstation 1050 to effect pairing and charging. If the first visualindicator 1060 is not activated, this may indicate that the chargingstation 1050 is not enabled. Hence, the first visual indicator 1060 andthe second visual indicator 1070 may be configured to be activatedindependently of each other such that the first visual indicator 1060may be activated while the second visual indicator 1070 is notactivated.

Once the remote control device 1032 has been physically connected to thedocking port 1052 of the charging station 1050, the first visualindicator 1060 may be deactivated, i.e., turned OFF, and at least one ofthe lights defining the second visual indicator 1070 may be activated toconvey to the operator that the remote control device 1032 has beenphysically connected to the docking port 1052, see FIG. 28B. Oncedocking of the remote control device 1032 has occurred, the remotecontrol device 1032 will attempt to pair with the vehicle controller 103and the rechargeable power source 180 of the remote control device 1032will begin to be charged by the charging station 1050. Lights definingthe second visual indicator 1070 may be activated serially, such as fromleft to right as viewed in FIGS. 26, 27 and 28B, to indicate the statusof the charging operation of the power source 180 or the charging stateof the rechargeable power source 180 when coupled to the chargingstation 1050. Once the rechargeable power source 180 is fully charged,all lights defining the second indicator 1070 may be activated, i.e.,turned ON, see FIG. 28C.

FIGS. 29A-29C provide an alternative embodiment, as compared to that ofFIGS. 28A-28C, for the activating and deactivating of the first visualindicator 1060 and the second visual indicator 1070 during physicalconnection and pairing of the remote control device 1032 with thedocking port 1052 of the charging station 1050. The embodiment of FIG.29A-29C can be utilized for all charge/pair cycles such as an initialcycle after vehicle 10 is powered ON from an OFF state as well assubsequent charge cycles occurring before vehicle 10 is powered OFF. Asdescribed above, when a vehicle 10 comprising the charging station 1050is powered up, i.e., turned from an OFF state to an ON state, the firstvisual indicator 1060 may be activated and, preferably, is pulsed ON andOFF to provide a visual display related to inserting the wearable remotecontrol device 1032 into the docking port 1052, while the second visualindicator 1070 remains OFF, see FIG. 28A and FIG. 29A. With the firstvisual indicator 1060 activated, i.e., pulsed ON and OFF, and the secondvisual indicator 1070 OFF, this indicates to an operator that thecharging station 1050 is enabled and functional and she/he needs tocouple the remote control device 1032 to the docking port 1052 of thecharging station 1050 to effect pairing and charging. Once the remotecontrol device 1032 has been physically connected to the docking port1052 of the charging station 1050, the first visual indicator 1060 mayremain activated so as to provide a steady-state ON display, and atleast one of the lights defining the second visual indicator 1070 may beactivated to convey to the operator that the remote control device 1032has been physically connected to the docket port 1052, see FIG. 29B.Once docking of the remote control device 1032 has occurred, the remotecontrol device 1032 will attempt to pair with the vehicle controller 103and the rechargeable power source 180 of the remote control device 1032will begin to be charged by the charging station 1050. Lights definingthe second visual indicator 1070 may be activated serially, such as fromleft to right as viewed in FIGS. 26, 27, 29B and 29C, to indicate thestatus of the charging operation of the power source 180 or the chargingstate of the rechargeable power source 180 when coupled to the chargingstation 1050. Once the rechargeable power source 180 is fully charged,all lights defining the second indicator 1070 may be activated, i.e.,turned ON, and the first visual indicator 1060 may be deactivated, i.e.,turned OFF, see FIG. 29C.

Because the first visual indicator 1060 remains activated, as shown inFIG. 29B, while the rechargeable power source 180 is charging, the firstvisual indicator 1060 and the second visual indicator 1070 both providecues to the operator that the remote control device 1032 should remainconnected with the charging station 1050 and that charging of therechargeable power source 180 is not complete until the first visualindicator 1060 is deactivated and all the lights of the second visualindicator 1070 are activated, i.e., see FIG. 29C.

In FIG. 28B, FIG. 28C, FIG. 29B and FIG. 29C, the individual lights ofthe second visual indicator 1070 can become activated, or turned on, oneafter the other which can be described as making the second visualindicator 1070 “grow.” As noted above, a desired charge state, e.g., asubstantially full charge state, of the rechargeable power source 180can be achieved by charging the rechargeable power source 180 at thecharging station in five seconds or less. If, for example, the secondvisual indicator 1070 has five discrete segments, or lights, a timing ofthe “growing” of the second visual display 1070 can be configured suchthat the time period between activating each of the five lights is aboutone second (+/−5%), such that activation of all of the lights, includingthe fifth light, indicates that the rechargeable power source is fullycharged. Alternatively, embodiments in accordance with the presentdisclosure contemplate the timing between activating each of the firstfour segments, LEDs, or lights of the second visual indicator 1070 canbe about 1.2 seconds (+/−5%) and activating the fifth and final segmentoccurs about 200 ms (+/−5%) after activation of the previous, or fourth,light. One benefit of having a non-uniform timing delay betweenactivating the light segments of the second visual indicator 1070 is toreduce the chance of an operator misunderstanding the lighting cues,removing the remote control device 1032 too early, and therebypreventing a full charge of the rechargeable power source 180.

In either embodiment involving the activation of the first visualindicator 1060 (i.e., FIGS. 28A-28C or FIGS. 29A-29C), if therechargeable power source 180 can not be charged, then the first visualdisplay 1060 may flash or pulse ON and OFF to provide a visual displayindicating an error, while the second visual display 1070 is turned OFF,see FIG. 28I. The error may be related to the rechargeable power source180, the charging station 1050 or both being defective. The rate atwhich the first visual indicator 1060 is flashed ON and OFF to indicatean error may vary in frequency as compared to the rate at which thefirst visual indicator 1060 is pulsed ON and OFF when the vehicle 10 ispowered up.

As noted above, once the rechargeable power source 180 has been fullycharged, all lights of the second visual indicator 1070 may beactivated. All lights of the second visual indicator 1070 may also bepulsed to provide the operator with an intermittent display as a cue toperform an action as a test to confirm that the remote control device1032 is functional and can communicate to the vehicle 10, i.e., thatpairing has been successful. The remote control device 1032 may furthercomprise a horn button 197B and a brake button 197C, similar to the hornand brake buttons 197B, 197C provided on the remote control device 32,see FIG. 4 . The action as a test to confirm that the remote controldevice 32 is functional and can communicate with the vehicle maycomprise pressing the horn button 197B to determine if a horn on thevehicle 10 is activated and/or pressing the brake button 197C todetermine if brakes on the vehicle are actuated. Once the test has beensuccessfully completed, all lights of the second visual indicator 1070may be activated continuously to define a steady-state display. Hence,the second visual indicator 1070 may define an intermittent display, asteady-state display, or a display where less than all of the lights areactivated, i.e., a partially filled display, based on the information tobe conveyed to the operator/user. If the test is not completedsuccessfully, the first visual indicator 1060 may flash or pulse ON andOFF to indicate an error, while the second visual indicator 1070 isturned OFF, see FIG. 28I. The error may occur due to pairing between theremote control device 1032 and the vehicle controller 103 not occurringsuccessfully. The rate at which the first visual indicator 1060 isflashed or pulsed ON and OFF to indicate that the test was not completedsuccessfully may vary in frequency from when the first visual indicator1060 is pulsed ON and OFF when the vehicle 10 is powered up.

As noted above, after the vehicle has been turned OFF and ON, therechargeable power source 180 is successfully fully charged and the testis successfully completed, all lights of the second visual indicator1070 may be activated continuously to define a steady-state display. If,after the rechargeable power source 180 has been successfully fullycharged and the test has been successfully completed, operation of thevehicle 10 and the remote control device 1032 cause the rechargeablepower source 180 to consume some of its charge such that the operator,before the vehicle is turned OFF, again connects the remote controldevice 1032 to the docket port 1052 for charging. After charging, thesecond visual indicator 1070 may not pulse to cue the operator toperform the test even though the rechargeable power source 180 may againreach full charge. Because the vehicle 10 has not been turned OFF andback ON since the last successful test, the second visual indicator 1070may not be pulsed to cue the operator to perform the test again butinstead, remain in its steady state display indicating the rechargeablepower source 180 is fully charged.

Once the rechargeable power source 180 has been fully charged and thetest has been completed successfully, which indicates that pairing hasbeen completed successfully, the first visual indicator 1060 may remainOFF and all lights of the second visual indicator 1070 may remain ON todefine a steady-state display. When the first and second visualindicators 1060 and 1070 are in these states, see FIG. 28E, this mayindicate to the operator that a pairing status between the remotecontrol device 1032 and the vehicle controller 103 is positive andactive and the vehicle 10 may be operated via the remote control device1032. During use of the remote control device 1032 to operate thevehicle 10, the rechargeable power source 180 will lose charge overtime, which will be indicated by the second visual indicator 1070, i.e.,lights extending from right to left as viewed in FIGS. 26, 27 and 28Fwill be deactivated or turned OFF, to indicate the decreasing level ofcharge of the power source 180 when the remote control device 1032 isnot coupled to the charging station 1050. When the charge is low, only asingle light of the second visual indicator 1070 may be activated andthe first visual indicator 1060 may be turned ON to provide asteady-state display signaling the operator that she/he needs to chargethe power source 180, see FIG. 28G. Hence, the first visual indicator1060 may define an intermittent display, see FIGS. 28A and 28I, or asteady-state display, see FIGS. 28G and 29B. It is also noted that thefirst and second visual indicators 1060 and 1070, when activated asillustrated in FIG. 28G, both provide steady state displays. When thecharge on the rechargeable power source 180 has been depleted, thesecond visual indicator 1070 may be turned OFF and the first visualindicator 1060 may be pulsed to indicate to the operator that the powersource 180 needs to be charged, see FIG. 28H.

As noted above, the rate at which the first visual indicator 1060 isflashed ON and OFF to indicate an error may be at a different frequencyas compared to the rate at which the first visual indicator 1060 ispulsed ON and OFF when the vehicle 10 is powered up. The error may, forexample, relate to an error with the charging station 1050 such that itis unable to charge the remote control device 1032. The error may also,for example, relate to an error with the remote control device 1032 orits power source 180 such that it is unable to receive a charge from thecharging station 1050. Furthermore, the error may, for example, involveboth the charging station 1050 and the remote control device 1032 suchthat there are communication messages between the two devices that arenot being received by the intended recipient of the communicationmessage.

As noted, the second visual indicator 1070 when activated can provideone of an intermittent display, as shown in the example of FIG. 28D,which may indicate to an operator to perform an action, or asteady-state display as shown in the example of FIG. 28E, which mayindicate to an operator that the remote control device 1032 is fullyready to use.

Also, when the first visual indicator 1060 and the second indicator 1070are concurrently activated, the first visual indicator 1060 and thesecond visual indicator 1070 can each provide respective steady-statedisplays as shown in the example of FIG. 28G, which can indicate thatthe rechargeable power source 180 has a low charge.

In the example of FIG. 28A, the first visual indicator 1060 may pulse asa way to define a visual display related to inserting the wearableremote control device 1032 into the charging station 1050.

As noted above, the example of FIG. 28I includes the first visualindicator flashing so as to provide a display indicative of theoccurrence of some error. This is only an example and, more generally,at least one embodiment of the present disclosure contemplates that thefirst visual indicator 1060 or the second visual indicator 1070 can,either individually or in combination with one another, provide a visualdisplay related to a charging error occurring with the charging station1050 or the rechargeable power source 108.

As noted above, the example of FIG. 28I includes the first visualindicator 1060 flashing so as to provide a display indicative of theoccurrence of some error. This is only an example and, more generally,at least one embodiment of the present disclosure contemplates that thefirst visual indicator 1060 or the second visual indicator 1070 can,either individually or in combination with one another, provide a visualdisplay related to a pairing error occurring between the wearable remotecontrol device 1032 and the vehicle 10. As explained earlier, the term“pairing” (as used herein) describes a secure process whereby thewireless remote control device 1032 and vehicle controller 103 identifyeach other as valid command and response devices. A pairing error canoccur as the two devices try to initially pair with one another and failor a pairing error can occur after a successful pairing such that thepairing is somehow interrupted or lost.

As noted above, the example of FIG. 28I includes the first visualindicator 1060 flashing so as to provide a display indicative of theoccurrence of some error. This is only an example and, more generally,at least one embodiment of the present disclosure contemplates that thefirst visual indicator 1060 or second visual indicator 1070 can, eitherindividually or in combination with one another, provide a visualdisplay related to a communication error occurring between the wearableremote control device 1032 and the controller 103. Once paired, theremote control device 1032 and the controller 103 both act as sendersand receivers of messages passed between the two according to apredetermined communications protocol. Communication errors can include,for example, when one of the devices does not receive an expectedmessage.

Having thus described the invention of the present application in detailand by reference to embodiments thereof, it will be apparent thatmodifications and variations are possible without departing from thescope of the invention defined in the appended claims.

What is claimed is:
 1. A system comprising: a materials handlingvehicle; a wearable remote control device comprising: a wirelesscommunication system including a wireless transmitter; and arechargeable power source; a receiver at the vehicle for receivingtransmissions from the wireless transmitter; a controller at the vehiclethat is communicably coupled to the receiver, the controller beingresponsive to receipt of the transmissions from the remote controldevice; and a charging station at the vehicle, the charging station forcharging the rechargeable power source of the wearable remote controldevice, the charging station comprising a visual indicator configured toindicate a pairing status between the wearable remote control device andthe vehicle controller.
 2. The system of claim 1, wherein the visualindicator displays a first color when the remote control device isattached to the charging station.
 3. The system of claim 2, wherein thevisual indicator displays a second color when the remote control devicehas been paired to the vehicle controller.
 4. The system of claim 1,wherein the visual indicator provides one of a flash display or a fullyfilled display.
 5. The system of claim 1, wherein the visual indicatorprovides a visual indication as a cue for an operator to perform anaction.
 6. The system of claim 5, wherein the action is a test toconfirm that the remote control device is functional and can communicatewith the vehicle.
 7. A method for coupling a wearable remote controldevice to a charging station, wherein the wearable remote control devicecomprises a wireless transmitter, a rechargeable power source, and atleast one control causing the wireless transmitter to wirelesslytransmit a request to a controller of a materials handling vehicle; andwherein the materials handling vehicle comprises a receiver forreceiving transmissions from the wireless transmitter; the controllerbeing responsive to receipt of the transmissions from the remote controldevice; the charging station configured for charging the rechargeablepower source of the wearable remote control device and comprising avisual indicator, the method comprising displaying, by the visualindicator, an indication of a pairing status between the wearable remotecontrol device and the vehicle controller.
 8. A system comprising: amaterials handling vehicle; a wearable remote control device comprising:a wireless communication system including a wireless transmitter; and arechargeable power source; a receiver at the vehicle for receivingtransmission from the wireless transmitter; a controller at the vehiclethat is communicably coupled to the receiver, the controller beingresponsive to receipt of the transmissions from the remote controldevice; and a charging station at the vehicle, the charging station forcharging the rechargeable power source of the wearable remote controldevice, the charging station comprising: a first visual indicatorconfigured to indicate at least one of: a charging state of therechargeable power source when coupled to the charging station, acharging state of the rechargeable power source when removed from thecharging station, a pairing status between the wearable remote controldevice and the vehicle controller, or that the remote control device isphysically connected to the charging station; and a second visualindicator configured to indicate at least another of: a charging stateof the rechargeable power source when coupled to the charging station, acharging state of the rechargeable power source when removed from thecharging station, a pairing status between the wearable remote controldevice and the vehicle controller, or that the remote control device isphysically connected to the charging station.
 9. The system of claim 8,wherein the first visual indicator and the second visual indicator areconfigured to be activated independently of each other such that eitherthe first visual indicator is activated while the second visualindicator is not activated or the second visual indicator is activatedwhile first visual indicator is not activated.
 10. The system of claim8, wherein the first visual indicator when activated provides one of anintermittent display or a steady-state display.
 11. The system of claim10, wherein the intermittent display is operational at a first pulsingrate or a second pulsing rate, wherein the first and second rates varyin frequency.
 12. The system of claim 8, wherein the second visualindicator when activated provides one of an intermittent display, apartially filled display or a steady-state display.
 13. The system ofclaim 8, wherein the first visual indicator and the second visualindicator are configured to be concurrently activated.
 14. The system ofclaim 8, wherein the first visual indicator is located proximate to adocking port of the charging station configured to receive the wearableremote control device and is shaped to correspond to a graphic providedon the wearable remote control device to aid a user in positioning andconnecting the wearable remote control device to the docking port of thecharging station.
 15. The system of claim 8, wherein the first visualindicator defines a visual display related to inserting the wearableremote control device into the charging station.
 16. The system of claim8, wherein the first or second visual indicators either individually orin combination with one another provide a visual display related to thecharging station being enabled or disabled.
 17. The system of claim 8,wherein the first or second visual indicators either individually or incombination with one another provide a visual display related to acharging error occurring with the charging station or the rechargeablepower source.
 18. The system of claim 8, wherein the first or secondvisual indicators either individually or in combination with one anotherprovide a visual display related to a pairing error occurring betweenthe wearable remote control device and the vehicle.
 19. The system ofclaim 8, wherein the first or second visual indicators eitherindividually or in combination with one another provide a visual displayrelated to a communication error occurring between the wearable remotecontrol device and the controller.
 20. The system of claim 8, whereinwhen the vehicle is turned on, the first indicator pulses until theremote control device is connected to a docking port of the chargingstation such that the first indicator is turned OFF when the remotecontrol device is connected to the docking port.
 21. The system of claim8, wherein when the vehicle is turned on, the first indicator pulsesuntil the remote control device is connected to a docking port of thecharging station, changes to a steady state ON display after the remotecontrol device is connected to the docking port and remains ON providingthe steady state ON display until the rechargeable power source is fullycharged.